Cleansing articles for skin or hair

ABSTRACT

The present invention relates to disposable, personal cleansing articles useful for cleansing the skin or hair. These articles are used by the consumer by wetting the dry article with water and then rubbing the article against the skin or hair. The article comprises a water insoluble substrate having a cleansing surface that contains apertures of a certain size and frequency, and a lathering surfactant releasably associated with the substrate. Preferably, the articles of the present invention further comprise a conditioning component.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a divisional of copending U.S. patentapplication Ser. No. 09/318,676, filed May 25, 1999, which is acontinuation-in-part (CIP) of the following copending U.S. patentapplications: U.S. Ser. No. 09/065,991, filed Apr. 24, 1998, in thenames of Timothy John Fowler, Lourdes Dessus Albacarys, and DavidMichael McAtee (P&G Case 6335R); U.S. Ser. No. 08/861,750, filed May 22,1997 in the names of Erik John Hasenoehrl, Lourdes Dessus Albacarys, andTimothy John Fowler (P&G Case 6652); U.S. Ser. No. 09/148,540, filedSep. 4, 1998 in the names of Erik John Hasenoehrl and David MichaelMcAtee (P&G Case 6819); and U.S. Ser. No. 09/152,034, filed Sep. 11,1998 in the names of David Michael McAtee, Nicholas James Nissing, ErikJohn Hasenoehrl, and David William Cabell (P&G Case 6840).

TECHNICAL FIELD

[0002] The present invention relates to disposable personal cleansingarticles useful for cleansing, and optionally conditioning, the skin orhair, and more particularly to a disposable cleansing, article having asubstrate, comprising either single or multiple layers, which contains aplurality of apertures along with a lathering surfactant component.These articles are used by the consumer by wetting the article, whichmay be dry, with water and by thereafter forming a lather by rubbing thearticle against itself and/or against skin or hair.

BACKGROUND OF THE INVENTION

[0003] Personal cleansing products have traditionally been marketed in avariety of forms such as bar soaps, creams, lotions, and gels. Thesecleansing formulations have attempted to satisfy a number of criteria tobe acceptable to consumers. These criteria include cleansingeffectiveness, skin feel, mildness to skin, hair, and ocular mucosae,and lather volume. Ideal personal cleansers should gently cleanse theskin or hair, cause little or no irritation, and not leave the skin orhair overly dry after frequent use. Personal cleansing products arefrequently used with, or marketed in the form of, articles that employ asubstrate or other implement that carries a cleansing material or isused to deliver a cleansing material to the skin or hair.

[0004] Traditional forms of personal cleansing products and articles maybe very useful for providing efficacious cleansing and lathering. Suchconventional products and articles, however are less suitable for alsosimultaneously providing other desirable effects such as delivering askin or hair conditioning benefit. One solution to this problem is touse separate cleansing and conditioning products or articles. However,this is not always convenient or practical, and many consumers wouldprefer to use a single article which can both cleanse and condition theskin or hair. In a typical cleansing composition or product, theconditioning ingredients are difficult to formulate because manyconditioners are incompatible with the surfactants, resulting in anundesirable non-homogenous mixture. To obtain a homogeneous mixture withconditioning ingredients, and to prevent the loss of conditioningingredients before deposition, additional ingredients, e.g. emulsifiers,thickeners, and gellants are often added to suspend the conditioningingredients within a surfactant mixture. This results in anaesthetically pleasing homogenous mixture, but often results in poordeposition of conditioning ingredients onto skin or hair because theconditioners are emulsified and not efficiently released duringcleansing. Also, many conditioning agents have the disadvantage ofsuppressing lather generation. Lather suppression is a problem becausemany consumers seek cleansing articles that provide a rich, creamy, andgenerous lather.

[0005] Therefore, it is seen that conventional cleansing products andarticles which attempt to combine surfactants and other materials suchas conditioning ingredients suffer from disadvantages inherentlyresulting from the incompatibilities of surfactants and conditioners. Aneed clearly exists to develop cleansing systems which provide effectivecleansing, effective lathering and yet can also, if desired,consistently provide other benefits such as sufficient conditioning in asingle article.

[0006] It is also highly desirable to deliver cleansing and preferablyconditioning benefits from a disposable, single use article. Disposablearticles are convenient because they obviate the need to carrycumbersome bottles, bars, jars, tubes, and other forms of both cleansingand conditioning articles. Disposable articles are also a more sanitaryalternative to the use of a sponge, washcloth, or other cleansingimplement intended for multiple reuse, because such implements developbacterial growth, unpleasant odors, and other undesirablecharacteristics related to repeated use.

[0007] Accordingly, it is an object of the present invention to providewashcloth-like articles for cleansing, and preferably also, conditioningthe skin or hair when the articles are used wetted with water and rubbedagainst the skin or hair.

[0008] It is another object of the present invention to provide suchcleansing articles which are disposable and intended for single use.

[0009] It is another object of the present invention to provide suchcleansing articles which are mild to the skin or hair.

[0010] It is another object of the present invention to provide suchcleansing articles which, upon wetting, are capable of generatingespecially desirable amounts of lather.

SUMMARY OF THE INVENTION

[0011] The present invention relates to disposable, single use personalcleansing articles especially useful for cleansing facial skin. Eachsuch article comprises a) a water-insoluble, non-woven substrate havingat least one cleansing surface; and b) from about 0.5% to 250% by weightof the substrate of a lathering surfactant which is releasablyassociated with the substrate. The cleansing surface of the substratecontains a plurality of apertures which range in size from about 0.5 mmto 5 mm in diameter. These apertures are located within said cleansingsurface of the substrate at a frequency of from about 0.5-12 aperturesper linear centimeter. Preferred multiple layer cleansing articles ofthis invention utilize a two-ply substrate wherein one or both plies areapertured. Also preferably at least one of the plies of the substrate iswet extensible and the second ply is less wet extensible than the firstply. Preferred articles are also substantially dry prior to use andcontain one or more water-soluble or water-insoluble conditioning agentsin addition to the lathering surfactant component.

[0012] The present invention also relates to methods for manufacturingcleansing articles of the configuration describe herein. Also, thepresent invention provides methods for cleansing, and optionallyconditioning, the skin or hair using the articles described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a plan view illustration of one embodiment of acleansing article of the present invention, the article including anextensible, apertured first layer and a less extensible second layer,with the first layer shown facing the viewer, and with a portion of thefirst layer shown cut away to show a continuous network of generallyparallel sets of intersecting lines of adhesive which serve to bond thefirst layer to the second layer, the bonded region defining generallydiamond-shaped unbonded regions.

[0014]FIG. 2 is an illustration of another embodiment of a cleansingarticle of the present invention, the article including an extensible,apertured first layer and a less extensible second layer, with the firstlayer shown facing the viewer, and with a portion of the first layershown cut away to show a continuous network of adhesive which serves tobond the first layer to the second layer, the bonded region defininggenerally circular-shaped unbonded regions.

[0015]FIG. 3 is a plan view illustration of another embodiment of acleansing article of the present invention, the article including anextensible, apertured first layer and a less extensible second layer,with the first layer shown facing the viewer, and with a portion of theapertured layer shown cut away to show generally parallel, spaced apartzones of adhesive extending generally parallel to the machine directionsof the apertured layer and the non-apertured layer.

[0016]FIG. 4 is an illustration of a portion of the cleansing articleshown in FIG. 1, FIG. 4 being enlarged relative to FIG. 1 to illustratethe apertures in the extensible first layer and creping ridges in theapertured layer.

[0017]FIG. 5A is a cross-sectional illustration of the cleansing articleof the present invention taken along the direction indicated by line 5-5in FIG. 1, and showing the article prior to wetting of the aperturedfirst layer.

[0018]FIG. 5B is a cross-sectional illustration taken along thedirection indicated by line 5-5 in FIG. 1, and showing the article afterwetting of the apertured first layer.

[0019]FIG. 6 is an illustration of a paper machine which can be used tomake cellulosic paper webs that can be used in forming the aperturedsubstrate portion of the cleansing articles herein.

[0020]FIG. 7 is an illustration of a forming element which can be usedto manufacture a cellulosic paper web with apertures that can beemployed in the articles herein.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The essential elements of cleansing articles of the presentinvention, i.e., the apertured water-insoluble substrate and thelathering surfactant, as well as a wide variety of optional elements,are described in detail as follows. All percentages and ratios usedherein, unless otherwise indicated, are by weight and all measurementsmade are at 25° C., unless otherwise designated. The invention hereofcan comprise, consist of, or consist essentially of, the essential aswell as optional ingredients and components described therein.

[0022] By a “lathering surfactant” is meant a surfactant, which whencombined with water and mechanically agitated generates a foam orlather. Preferably, these surfactants should be mild, which means thatthese surfactants provide sufficient cleansing or detersive benefits butdo not overly dry the skin or hair (e.g., removing too much natural oiland/or moisture), and yet meet the lathering criteria described above.

[0023] The term “lathering product” or “lathering article,” as usedherein, means that the product or article contains enough of thesurfactants described herein that it can generate≧30 ml of LatherVolume, as described herein in the Lather Volume Test. These LatherVolume measurements are conducted with a medium hardness water (8-10grains per gallon) at 95° C.

[0024] The terms “disposable” or “single use”, are used herein in theirordinary sense to mean a article that is disposed or discarded after oneusage event.

[0025] The term “conditioning component,” as used herein, means acombination of the conditioning agents.

[0026] The term “water-activated,” as used herein, means that thepresent invention is presented to the consumer in dry form to be usedafter it is wetted with water. It is found that these articles produce alather or are “activated” by contacting them with water and then furthersubjecting the article to mechanical forces, such as rubbing.

[0027] The term “substantially dry,” as used herein, means that prior touse the article is substantially free of water and generally feels dryto the touch. Thus, the articles of the present invention will generallycomprise less than about 10% by weight of water, preferably less thanabout 5% by weight of water, and more preferably less than about 1% byweight of water, the forgoing measured in a dry environment, e.g., lowhumidity. One of ordinary skill in the art would recognize that thewater content of a article such as in the present invention can varywith the relative humidity of the environment.

[0028] The term “mild” as used herein in reference to the latheringsurfactants and articles of the present invention means that thearticles of the present invention demonstrate skin mildness comparableto a mild alkyl glyceryl ether sulfonate (AGS) surfactant basedsynthetic bar, i.e. synbar. Methods for measuring mildness, or inverselythe irritancy, of surfactant containing articles, are based on a skinbarrier destruction test. In this test, the milder the surfactant, thelesser the skin barrier is destroyed. Skin barrier destruction ismeasured by the relative amount of radio-labeled (tritium labeled) water(3H-H₂O) which passes from the test solution through the skin epidermisinto the physiological buffer contained in the diffusate chamber. Thistest is described by T. J. Franz in the J. Invest. Dermatol., 1975, 64,pp. 190-195; and in U.S. Pat. No. 4,673,525, to Small et al., issuedJun. 16, 1987, which are both incorporated by reference herein in theirentirety. Other testing methodologies for determining surfactantmildness well known to one skilled in the art can also be used.

[0029] The personal cleansing articles of the present invention comprisethe following essential components: (A) a water-insoluble substrate,wherein at least a portion of said substrate contains apertures, and (B)at least one lathering surfactant added onto or impregnated into thesubstrate. The articles of the present invention can further optionallycomprise a conditioning component added onto or impregnated into thesubstrate.

[0030] APERTURED WATER INSOLUBLE SUBSTRATE

[0031] The products of the present invention comprise a water insolublesubstrate having at least one cleansing surface. By “water insoluble” ismeant that the substrate does not dissolve in or readily break apartupon immersion in water. The water insoluble substrate is the implementor vehicle for delivering the lathering surfactant and optionally theconditioning component of the present invention to the skin or hair tobe cleansed and conditioned. Without being limited by theory, it isbelieved that the substrate, by providing mechanical forces andagitation provides a lather generating effect and also aids in thedeposition of the conditioning component.

[0032] A wide variety of materials can be used as the substrate. Thefollowing nonlimiting characteristics are desirable: (i) sufficient wetstrength for use, (ii) sufficient abrasivity, (iii) sufficient loft andporosity, (iv) sufficient thickness, and (v) appropriate size.

[0033] Nonlimiting examples of suitable insoluble substrates which meetthe above criteria include nonwoven substrates, woven substrates,hydroentangled substrates, air entangled substrates, natural sponges,synthetic sponges, polymeric netted meshes, and the like. Preferredembodiments employ nonwoven substrates since they are economical andreadily available in a variety of materials. By nonwoven is meant thatthe layer is comprised of fibers which are not woven into a fabric butrather are formed into a sheet, mat, or pad layer. The fibers can eitherbe random (i.e., randomly aligned) or they can be carded (i.e. combed tobe oriented in primarily one direction). Furthermore, the nonwovensubstrate can be composed of a combination of layers of random andcarded fibers.

[0034] Nonwoven substrates may be comprised of a variety of materialsboth natural and synthetic. By natural is meant that the materials arederived from plants, animals, insects or byproducts of plants, animals,and insects. By synthetic is meant that the materials are obtainedprimarily from various man-made materials or from natural materialswhich have been further altered. The conventional base starting materialis usually a fibrous web comprising any of the common synthetic ornatural textile-length fibers, or mixtures thereof.

[0035] Nonlimiting examples of natural materials useful in the presentinvention are silk fibers, keratin fibers and cellulosic fibers.Nonlimiting examples of keratin fibers include those selected from thegroup consisting of wool fibers, camel hair fibers, and the like.Nonlimiting examples of cellulosic fibers include those selected fromthe group consisting of wood pulp fibers, cotton fibers, hemp fibers,jute fibers, flax fibers, and mixtures thereof.

[0036] Nonlimiting examples of synthetic materials useful in the presentinvention include those selected from the group consisting of acetatefibers, acrylic fibers, cellulose ester fibers, modacrylic fibers,polyamide fibers, polyester fibers, polyolefin fibers, polyvinyl alcoholfibers, rayon fibers, polyurethane foam, and mixtures thereof. Examplesof some of these synthetic materials include acrylics such as acrilan,creslan, and the acrylonitrile-based fiber, orlon; cellulose esterfibers such as cellulose acetate, arnel, and acele; polyamides such asnylons (e.g., nylon 6, nylon 66, nylon 610, and the like); polyesterssuch as fortrel, kodel, and the polyethylene terephthalate fiber,dacron; polyolefins such as polypropylene, polyethylene; polyvinylacetate fibers; polyurethane foams and mixtures thereof. These and othersuitable fibers and the nonwoven materials prepared therefrom aregenerally described in Riedel, “Nonwoven Bonding Methods and Materials,”Nonwoven World (1987); The Encyclopedia Americana, vol. 11, pp. 147-153,and vol. 26, pp. 566-581 (1984); U.S. Pat. No. 4,891,227, to Thaman etal., issued Jan. 2, 1990; and U.S. Pat. No. 4,891,228 which are allincorporated by reference herein in their entirety.

[0037] Nonwoven substrates made from natural materials consist of websor sheets most commonly formed on a fine wire screen from a liquidsuspension of the fibers. See C. A. Hampel et al., The Encyclopedia ofChemistry, third edition, 1973, pp. 793-795 (1973); The EncyclopediaAmericana, vol. 21, pp. 376-383 (1984); and G. A. Smook, Handbook ofPulp and Paper Technologies, Technical Association for the Pulp andPaper Industry (1986); which are incorporated by reference herein intheir entirety.

[0038] Substrates made from natural materials useful in the presentinvention can be obtained from a wide variety of commercial sources.Nonlimiting examples of suitable commercially available paper layersuseful herein include Airtex®, an embossed airlaid cellulosic layerhaving a base weight of about 85 grams per square meter, available fromJames River, Green Bay, Wis.; and Walkisoft®, an embossed airlaidcellulosic having a base weight of about 90 grams per square meter,available from Walkisoft U.S.A., Mount Holly, N.C.

[0039] Methods of making nonwoven substrates, including aperturedsubstrates, are well known in the art. Generally, these nonwovensubstrates can be made by air-laying, water-laying, meltblowing,coforming, spinbonding, or carding processes in which the fibers orfilaments are first cut to desired lengths from long strands, passedinto a water or air stream, and then deposited onto a screen or beltthrough which the fiber-laden air or water is passed. The resultinglayer, regardless of its method of production or composition, is thensubjected to at least one of several types of bonding operations toanchor the individual fibers together to form a self-sustaining web. Inthe present invention the nonwoven layer can be prepared by a variety ofprocesses including hydroentanglement, thermally bonding orthermo-bonding, and combinations of these processes. Moreover, thesubstrates used in the present invention can consist of a single layeror multiple layers. In addition, a multilayered substrate can includefilms and other nonfibrous materials.

[0040] The substrates used to form the personal cleansing articles ofthe present invention must contain apertures or openings in thecleansing surface of the substrate. Such apertures may be generallycircular in shape or may be openings of other shapes, including squares,rectangles, trapezoids, diamonds, hexagons, irregular shapes and thelike. Such apertures need not be uniform in size and shape, butpreferably will be substantially uniform in both size and shape.

[0041] The apertures in the cleansing surface of the substrate willgenerally range in average diameter between about 0.5 mm and 5 mm. Morepreferably, the apertures will range in size between about 1 mm to 4 mmin average diameter. Preferably no more than about 10% of the aperturesin the cleansing surface of the substrate will fall outside these sizeranges. More preferably no more than about 5% of the apertures in thecleansing surface will fall outside these size ranges. For apertureswhich are not circular in shape, the “diameter” of the aperture refersto the diameter of a circular opening having the same surface area asthe opening of the non-circular shaped aperture.

[0042] Within the cleansing surface of the substrate, the apertures willgenerally occur at a frequency of from about 0.5 to 12 apertures perstraight linear centimeter. More preferably the apertures in thecleansing surface will occur at a frequency of from about 1.5 to 6apertures per straight linear centimeter.

[0043] The apertures must at least be placed within the cleansingsurface of the substrate element herein. Such apertures need notprotrude completely through to the surface of the substrate which isopposite to the cleansing surface. When two or more plies or layers areused to form the water-insoluble substrate, apertures may or may not beplaced in all of the plies or layers. Frequently, as noted more fullyhereinafter, the substrate may comprise two layers one of which includesthe cleansing surface and is apertured. The other layer or ply whichforms a backing for the substrate with the cleansing surface is notapertured.

[0044] Apertures may be formed in the cleansing surface of thewater-insoluble substrate as such a substrate, or layer thereof, isbeing formed or fabricated. Alternatively, apertures may be formed inthe cleansing surface after the substrate, or ply or layer thereof,comprising the cleansing surface has been completely formed.

[0045] Nonwoven substrates made from synthetic materials useful in thepresent invention can be obtained from a wide variety of commercialsources. Nonlimiting examples of suitable nonwoven layer materialsuseful herein include HEF 40-047, an apertured hydroentangled materialcontaining about 50% rayon and 50% polyester, and having a basis weightof about 61 grams per square meter (gsm), available from Veratec, Inc.,Walpole, Mass.; HEF 140-102, an apertured hydroentangled materialcontaining about 50% rayon and 50% polyester, and having a basis weightof about 67 gsm, available from Veratec, Inc., Walpole, Mass.; Novonet®149-616, a thermo-bonded grid patterned material containing about 100%polypropylene, and having a basis weight of about 60 gsm available fromVeratec, Inc., Walpole, Mass.; Novonet® 149-801, a thermo-bonded gridpatterned material containing about 69% rayon, about 25% polypropylene,and about 6% cotton, and having a basis weight of about 90 gsm,available from Veratec, Inc. Walpole, Mass.; Novonet® 149-191, athermo-bonded grid patterned material containing about 69% rayon, about25% polypropylene, and about 6% cotton, and having a basis weight ofabout 120 gsm, available from Veratec, Inc. Walpole, Mass.; HEF Nubtex®149-801, a nubbed, apertured hydroentangled material, containing about100% polyester, and having a basis weight of about 84 gsm, availablefrom Veratec, Inc. Walpole, Mass.; Keybak® 951V, a dry formed aperturedmaterial, containing about 75% rayon, about 25% acrylic fibers, andhaving a basis weight of about 51 gsm, available from Chicopee, NewBrunswick, N.J.; Keybak® 1368, an apertured material, containing about75% rayon, about 25% polyester, and having a basis weight of about 47gsm, available from Chicopee, New Brunswick, N.J.; Duralace® 1236, anapertured, hydroentangled material, containing about 100% rayon, andhaving a basis weight from about 48 gsm to about 138 gsm, available fromChicopee, New Brunswick, N.J.; Duralace® 5904, an apertured,hydroentangled material, containing about 100% polyester, and having abasis weight from about 48 gsm to about 138 gsm, available fromChicopee, New Brunswick, N.J.; Chicopee® 5763, a carded hydroaperturedmaterial (8×6 apertures per inch, 3×2 apertures per cm), containingabout 70% rayon, about 30% polyester, and a optionally a latex binder(Acrylate or EVA based) of up to about 5% w/w, and having a basis weightfrom about 60 gsm to about 90 gsm, available form Chicopee, NewBrunswick, N.J.; Chicopee® 9900 series (e.g., Chicopee 9931, 62 gsm,50/50 rayon/polyester, and Chicopee 9950 50 gsm, 50/50 rayon/polyester),a carded, hydroentangled material, containing a fiber composition offrom 50% rayon/50% polyester to 0% rayon/100% polyester or 100% rayon/0%polyester, and having a basis weight of from about 36 gsm to about 84gsm, available form Chicopee, New Brunswick, N.J.; Sontara 8868, ahydroentangled material, containing about 50% cellulose and about 50%polyester, and having a basis weight of about 72 gsm, available fromDupont Chemical Corp. Preferred non-woven substrate materials have abasis weight of about from 24 gsm to about 96 gsm, more preferably fromabout 36 gsm to about 84 gsm, and most preferably from about 42 gsm toabout 78 gsm.

[0046] The substrate can be made into a wide variety of shapes and formsincluding flat pads, thick pads, thin sheets, ball-shaped implements,irregularly shaped implements, and having sizes ranging from providing acleansing surface area of at least about 5 cm². The exact size willdepend upon the desired use and product characteristics. Especiallyconvenient are square, circular, rectangular, or oval pads having acleansing surface area of from about 6 cm² to 1000 cm² preferably fromabout 65 cm² to about 775 cm², and more preferably from about 150 cm² toabout 400 cm², and a thickness of from about 1 mil to about 500 mil,preferably from about 5 mil to about 250 mil, and more preferably fromabout 10 mil to about 100 mil.

[0047] Furthermore, it is desirable for the substrates of the presentinvention to have rounded corners. This feature prevents the tendency ofwater to accumulate at the corners of an unrounded rectangular, e.g.,square, substrate. Comers, preferably all of the corners on thesubstrate, can be rounded to provide a radius of from about 1 to 4 cm.Preferably the rounded corners will have a radius of from about 2 to 3cm.

[0048] The water insoluble substrates of the present invention cancomprise one or more layers, each having different textures andabrasiveness. The differing textures can result from the use ofdifferent combinations of materials or from the use of differentmanufacturing processes or a combination thereof. A dual texturedsubstrate can be made to provide the advantage of having a more abrasiveside for exfoliation and a softer, absorbent side for gentle cleansing.In addition, separate layers of the substrate can be manufactured tohave different colors, thereby helping the user to further distinguishthe surfaces.

[0049] One especially preferred embodiment of the water-insolublesubstrate is one wherein the substrate includes at least two layers orplies. The first layer is extensible when it is wetted and is preferablyapertured. The second layer is less wet extensible when wetted than thefirst layer. Selected portions of the first layer are joined to thesecond layer to inhibit wet extension of the first layer in the plane ofthe first layer. When the first layer is wetted, the second layerconstrains extension of the first layer in the plane of the first layer.As a result, portions of the first layer deform, such as by buckling orpuckering, in the Z-direction (perpendicular to the plane of the firstlayer).

[0050] One embodiment of a water insoluble substrate having at least aportion that is wet extensible is illustrated in FIGS. 1-3 of thedrawings. In this embodiment, the present invention comprises a multiplelayer, i.e., two-ply, disposable wiping article 20. The disposablecleansing and conditioning article 20 comprises a substrate designatedgenerally by reference numeral 22. The substrate 22 comprises a firstlayer 100 and a second layer 200. The first layer 100 is extensible, andin particular is extensible when wetted, e.g., the first layer is wetextensible. By “wet extensible” is meant that a material has a tendencyto elongate in at least one direction when wetted. In general, “wetted”refers to wetting with aqueous solutions, such as water, which arecapable of inducing extension in the first layer. For example, waterrelaxes the crepe in foreshortened paper, thereby causing an extensionof the paper in at least one direction in the plane of the paper.Without being bound by theory, the relaxation of crepe may be a resultof the loss of hydrogen bonds within the paper structure due to thepresence of water. However, any fluid, mixture, or solution which couldcause this crepe relaxation would be considered to “wet” the article.The second layer 200 is relatively less wet extensible when wetted thanthe first layer 100. Extensibility is measured according to the “WetExtensibility Test” described below, and is reported as a percentage

[0051] Selected portions of the first layer 100 are joined, directly orindirectly, to second layer 200 to inhibit wet extension of the firstlayer in the plane of the first layer. In FIGS. 1 and 2, selectedportions of the first layer 100 are joined to the second layer 200 toprovide continuous bonded regions designated 110 and discrete unbondedregions 114.

[0052] In a preferred embodiment shown in FIG. 1, the bonded regions 110are shown as a continuous network of intersecting lines forminggenerally diamond-shaped unbonded regions 114. The width and spacing ofthe intersecting lines of bonded regions 110, may be adjusted to thedesired size and spacing of the diamond-shaped unbonded regions 114. Thecontinuous network of intersecting lines may be virtually any pattern,resulting in unbonded regions of virtually limitless geometric shapes,including, for example, squares, rectangles, and triangles. The networkneed not be completely continuous, nor limited to a pattern of straightor uniform lines, but may, for example, be a network resulting incircular, oval, or other non-polygonal geometric shapes. An adhesive,such as a hot melt adhesive, designated by reference numeral 300 inFIGS. 1-3, can be used to join the first layer 100 to second layer 200.

[0053] When the first layer is wetted, there is a tendency for the firstlayer 100 to expand along one or more directions in the plane of thefirst layer. (The plane of the first layer is parallel to the plane ofFIG. 1). However, because of the relatively lower wet extensibility ofthe second layer 200, the second layer constrains extension of the firstlayer 100 in the plane of the first layer. As a result, the unbondedregions 114 of the first layer 100 deform, such as by buckling orpuckering in the Z-direction, perpendicular to the plane of the firstlayer 100.

[0054]FIG. 5A is a cross-sectional illustration of the cleansing andconditioning article 20 prior to wetting of the first layer 100. Asshown in FIG. 5A, the wiping article is generally flat prior to wetting.FIG. 5B is a cross-sectional illustration similar to that of FIG. 5A,but showing the article 20 after wetting of the first layer 100. FIG. 5Bshows out of plane deformation of the first layer 100 upon wetting ofthe first layer 100. The Z-direction is indicated in FIGS. 5A and 5B.The deformation of the wetted first layer 100 provides the article 20with elevated ridges 120 which increase the wet texture, wet caliper(thickness) and wet bulk of the article 20. The elevated ridges 120 alsoprovide pockets 150 disposed between the unbonded portions of the firstlayer 100 and the underlying portions of the second layer. Inparticular, the article 20 has a wet caliper to dry caliper ratio whichis greater than 1.0, preferably at least about 1.1, more preferably atleast about 1.2, and most preferably at least about 1.4. The wet caliperto dry caliper ratio is a measure of the thickness of the article 20,when wetted, relative to the thickness of the dry article 20 prior towetting. The wet caliper to dry caliper ratio is measured according tothe procedure “Wet Caliper to Dry Caliper Ratio” provided hereinafter.

[0055] In the preferred embodiment shown in FIG. 1, the first layer 100is apertured, the first layer 100 comprising a plurality of apertures102 which extend through the thickness of the first layer 100. Aperturesadd greatly to the desired texture and bulk of wiping article 20. InFIGS. 1-3, apertures 102 are shown on only a portion of the first layer100 for clarity. When an apertured first layer is used, the deformationof the wetted first layer 100 again provides the article 100 withelevated ridges 120 which increase the wet texture, wet caliper(thickness) and wet bulk of the article 20. However, in this embodiment,the elevated ridges 120 have apertures 102 which provide a flow paththrough which liquids and/or small particles can enter the pockets 150.

[0056] Additionally, since the article 20, or alternate single plyapertured substrate, is used with, or includes a lathering agent, suchas a surfactant, the apertures 102 can aid in the incorporation of airduring the lathering process, thereby improving lather generation. Forinstance, a portion of the article 20 can be coated with or otherwisetreated with a surfactant composition, as described more fully below.The article 20 can be wetted with water to activate the surfactant, andthe airflow generated through the apertures 102 during use of thearticle (e.g. washing or wiping) can help to generate lather.

[0057] The size and number of the apertures 102 can influence the speedof lather generation and the quality of lather produced. A relativelysmall number of relatively large apertures 102 will tend to reduce thetime required to generate lather, but will yield relatively large latherbubbles with a translucent appearance. On the other hand, a relativelylarger number of relatively smaller apertures 102 will tend to reducebubble size, thereby increasing lather creaminess and opacity, but atthe expense of increasing the time required to generate lather.

[0058] Another advantage has been identified when first layer 100 isapertured. As shown in FIG. 5B, in addition to the formation of elevatedridges 120, the wet extension of first layer 100 around apertures 102forms what can best be described as cusps 106, or surface irregularitiesformed by the apertures 102. Cusps 106 give added texture to the surfaceon the side of apertured surface 22 of first layer 100. This addedtexture may be modified as needed by adjusting the size and spacing ofapertures 102.

[0059] Also depicted in FIG. 3, is another variation on theconfiguration of bonded and unbonded regions. In the embodiment shown,the bonded regions 110 are generally parallel, spaced apart regionswhich extend along substantially the full length of the article 20, anddefine generally parallel, spaced apart unbonded regions 114 of thefirst layer 100. In FIG. 3, the unbonded regions 114 extend alongsubstantially the full length of the article 20. An adhesive, designatedby reference numeral 300 in FIGS. 1 and 2 and numerals 300, 310A-310D inFIG. 3, can be used to join the first layer 100 to the second layer 200.

[0060] In a preferred embodiment, a wipe 20 of the present inventioncomprises an apertured cellulosic paper first layer bonded to asynthetic nonwoven in a continuous network of intersecting linesdefining diamond-shaped unbonded regions. This combination of materialsand bonding method and pattern provides for a preferred wipe thatexhibits increased texture and bulk on one side upon wetting, whilemaintaining relatively smooth softness on the other side, and has a wetcaliper greater than the dry caliper.

[0061] In addition to the above description, it has been found that anadditional processing step involving heating the substrate after bondingcan be used to further improve texture and bulk, as well as the generalaesthetic qualities of the wipe. Without being bound by theory, it isbelieved that the process of heating causes the thermoplastic adhesiveto contract, thereby further causing out-of-plane (Z-direction)deformation of the first layer, as well as the second layer. Bycontracting in the plane of the wipe article, both layers experience aZ-direction increase in caliper, giving increased overall caliper with apleasing quilted look.

[0062] For example, a wipe that has been adhesively bonded with an EVAhot melt adhesive (one suitable adhesive is a hot melt adhesivecommercially available as H1382-01 from Ato-Findley Adhesives ofWauwatosa, Wis.), may increase in caliper between 10-20% after apost-lamination heat treatment. In this case, a suitable hot meltadhesive is applied and the resulting article is cooled to roomtemperature. Heat treatment may then be performed, for example, raisingthe temperature to 100 degrees Celsius for 20 seconds is sufficient toinitiate contraction of the polymer network. While not being bound bytheory, it is believed that for this process to be effective, thepattern of bonding must be a continuous or essentially continuousnetwork. Discrete bond sites may not sufficiently contract to improvethe appearance of the article.

[0063] First Layer:

[0064] Referring to the components of the article 20 in more detail,suitable materials from which the first layer 100 can be formed includeforeshortened (such as by creping) wetlaid paper webs. Other suitablematerials can include woven materials, nonwoven materials, foams,battings, and the like.

[0065] The first layer 100 should be constructed to have a wetextensibility of at least 4 percent, more preferably at least about 10percent, and still more preferably at least about 20 percent. In oneembodiment, the first layer has a wet extensibility of at least about 25percent. Preferably, the difference between the wet extensibility of thefirst layer and the wet extensibility of the second layer (the wetextensibility of the second layer subtracted from the wet extensibilityof the first layer) is at least about 4 percent, more preferably atleast about 10 percent, and still more preferably at least about 25percent.

[0066] The fibers or filaments of the first layer 100 can be natural(e.g. cellulosic fibers such as wood pulp fibers, cotton linters, andbagasse fibers) or synthetic (e.g. polyolefins, rayon, polyamides orpolyesters), or combinations thereof.

[0067] In another preferred embodiment, the first layer 100 comprises awetlaid paper web of cellulosic wood pulp fibers which is foreshortenedat least about 4 percent, more preferably at least about 10 percent, andstill more preferably at least about 20 percent, by dry creping.Referring to FIG. 4, the first layer 100 is shown comprising creperidges 105 corresponding to the foreshortening of the first layer 100.The machine direction (MD) and cross machine direction (CD) areindicated in FIGS. 1-4. The machine direction corresponds to thedirection of manufacture of the paper web of first layer 100. The creperidges 105 are generally perpendicular to the machine direction, andgenerally parallel to the cross machine direction of the paper web offirst layer 100.

[0068] The paper web of the first layer 100 can have a basis weight ofbetween about 15 to about 65 grams per square meter. In a preferredembodiment, the basis weight of the first layer is between about 25 toabout 45 grams per square meter, and in a more preferred embodiment, thebasis weight of the first layer 100 is about 35 grams per square meter.

[0069] It is believed that the paper strength can significantly alterthe overall appearance of the complete article. The amount of crepeinput to the first layer is directly proportional to the amount ofplanar expansion and thereby the amount of caliper generated uponwetting. However, if the wet strength of the paper article isinsufficient, the “buckles” may collapse to form a more “wrinkled”product having less caliper. Therefore both crepe and wet strength canbe adjusted to provide an amount of texture based on the intended use ofthe article. Wet burst measurements can be made with a Thwing-AlbertBurst Tester model number 1300-77, which tests peak load of a fullywetted substrate. The test utilizes a 1.3 cm ball diameter, a 12.7cm/min ball velocity, and clamps the test sample around a 8.9 cm.diameter circle perpendicular to the motion of the ball. Peak load wetburst strengths are between 100 and 1200 grams per ply. More preferablybetween 400 and 700 grams per ply and most preferably between 500 and600 grams per ply.

[0070] In a more preferred embodiment, the first layer 100 comprises anapertured wetlaid paper web of cellulosic wood pulp fibers. Theapertures 102 can be formed in the first layer 100 in any suitablemanner. For instance, the apertures 102 can be formed in the first layer100 during formation of the paper web of the first layer 100, oralternatively, after the paper web of the first layer 100 ismanufactured. In one embodiment, the paper web of the first layer 100 isproduced according to the teachings of one or more of the following U.S.patents, which patents are incorporated herein by reference: U.S. Pat.No. 5,245,025 issued Sep. 14, 1993 to Trokhan et al.; U.S. Pat. No.5,277,761 issued Jan. 11, 1994 to Phan et al.; and U.S. Pat. No.5,654,076 issued Aug. 5, 1997 to Trokhan et al. In particular, U.S. Pat.No. 5,277,761 at Column 10 discloses formation of a paper web havingapertures.

[0071] Prior to wetting of the first layer, the creped first layer 100can have between about 0.5 and 50 apertures per square centimeter, andmore preferably between about 0.5 and 16 apertures per squarecentimeter. Wetting a creped paper web causes the web, if unrestrained,to expand in at least one direction, such as the machine direction, sothat the number of apertures 102 per square area after wetting can besmaller than the number of apertures per square area prior to wetting.Similarly, when apertures are formed in a paper web, and the paper webis subsequently creped, the number of apertures per square area prior tocreping will be smaller than the number of apertures per square areaafter creping. Accordingly references to paper web dimensions refer todimensions after creping and prior to wetting.

[0072] The apertures 102 can comprise between about 15 and about 75percent of the total surface of the first layer 100. The apertures 102shown in FIG. 2 are bilaterally staggered (staggered in both the machineand cross machine directions) in a repeating, nonrandom pattern. In oneembodiment, the first layer 100 comprises a paper web which is drycreped 25 percent (25 percent foreshortening) with greater than about 25percent wet extensibility, and has about 6 to 8 apertures, 102, persquare centimeter, the apertures 102 having a length 103 (FIG. 4) ofabout 0.25 to 0.46 centimeters and a width 104 of about 0.17 to 0.38centimeter, and a distance between apertures 106 of about 0.12 to toabout 0.20 centimeter.

[0073] The paper web is manufactured by first forming an aqueouspapermaking furnish. The furnish comprises papermaking fibers, and canfurther comprise various additives. U.S. Pat. No. 5,223,096 issued Jun.29, 1993 to Phan et al. is incorporated herein by reference for thepurpose of disclosing various wood pulps and papermaking additives.

[0074] A suitable paper web for making the first layer 100 can bemanufactured according to the following description. A papermakingfurnish is prepared from water and highly refined Kraft pulp derivedfrom northern softwoods (NSK), the paper furnish having a fiberconsistency of about 0.2 percent (dry fiber weight divided by the totalweight of the furnish equals 0.002). A dry strength additive such ascarboxymethyl cellulose (CMC) is added to the 100% NSK furnish in theamount of about 5 pounds of CMC solids per ton of dry papermakingfibers. A wet strength additive such as Kymene 557H (available fromHercules, Inc. of Wilmington, Del.) is added to the furnish in theamount of about 28 pounds of Kymene solids per ton of dry papermakingfibers.

[0075] Referring to FIG. 6, the furnish is deposited from a headbox 500of a papermaking machine to a forming element 600 at a fiber consistencyof about 0.2 percent. The forming element 600 is in the form of acontinuous belt in FIG. 6. The slurry of papermaking fibers is depositedon the forming element 600, and water is drained from the slurry throughthe forming element 600 to form an embryonic web of papermaking fibersdesignated by reference numeral 543 in FIG. 6.

[0076]FIG. 7 shows a portion of the forming element 600. The formingelement 600 has two mutually opposed faces. The face which is shown inFIG. 7 is the face which contacts the papermaking fibers of the webbeing formed. A description of a forming element of the type shown inFIG. 7 is provided in the above referenced U.S. Pat. Nos. 5,245,025;5,277,761; and 5,654,076.

[0077] The forming element 600 has flow restriction members in the formof resin protuberances 659. The forming element 600 shown comprises apatterned array of protuberances 659 joined to a reinforcing structure657, which may comprise a foraminous element, such as a woven screen orother apertured framework. The protuberances 659 extend above thereinforcing structure 657.

[0078] A suitable forming element 600 has about 6 protuberances 659 persquare centimeter of surface of the forming element 600, with theprotuberances 659 covering about 35 percent of the surface of theforming element 600, as viewed in FIG. 7, and the protuberancesextending 0.065 centimeter above the surface of the reinforcingstructure 657. The protuberances can have a machine direction length Xof about 0.384 centimeter and a cross machine direction width Y of about0.234 centimeter.

[0079] The reinforcing structure 657 is substantially fluid pervious,while the protuberances 659 are substantially fluid impervious.Accordingly, as the liquid in the papermaking furnish drains through theforming element, the papermaking fibers in the furnish will be retainedon the reinforcing structure 657, leaving apertures in the embryonic web543 corresponding generally in size, shape and location to the size,shape and location of the protuberances 659.

[0080] Referring back to FIG. 6, the embryonic web 543 is transferred toa conventional dewatering felt 550 with the aid of a vacuum pick up shoe560. The web 543 is transferred to the felt 550 at a fiber consistencyof about 4 percent. The web 543 is carried on the felt 550 to a nip 570formed between a vacuum pressure roll 572 and a Yankee dryer drum 575.The web 543 is dried on the Yankee drum 575 to a fiber consistency ofabout 96 percent, at which point the web is creped from the Yankee drum575 with a doctor blade 577 having a bevel angle of about 25 degrees andan impact angle of about 81 degrees. The web is wound on a reel at arate (lineal feet per second) which is 25 percent slower than thesurface speed of the Yankee drum (reel speed equals 0.75 times theYankee speed) to foreshorten the web about 25 percent. The foreshortenedweb can have a basis weight of about 33 grams per square meter, and athickness of about 12 to 13 mils (0.012 to 0.013 inch) as measured witha confining pressure of 95 grams per square inch and a load foot havinga diameter of 5 centimeters. The resulting foreshortened web can be usedto form a first layer 100 having a wet extensibility of at least about25 percent.

[0081] Second Layer:

[0082] The first layer 100 is joined to the second layer 200 toconstrain extension of selected portions of the first layer 100 when thefirst layer is wetted. The second layer 200 has a lower wetextensibility than that of the first layer 100.

[0083] Ply Bonding:

[0084] Selected portions of the first layer 100 can be joined directly(or indirectly such as through a third component) to the second layer200 in a predetermined bonding pattern to provide a plurality of bondedand unbonded regions of the first layer 100. In FIGS. 1-3, the bondedregions are designated 110, and the unbonded regions are designated 114.Each of the first and second layers 100 and 200 can have a machinedirection, and the first and second layers can be bonded so that themachine direction of the first layer is generally parallel to themachine direction of the second layer.

[0085] The first layer 100 and the second layer 200 can be joined usingany suitable method, including but not limited to adhesive bonding,mechanical bonding, thermal bonding, mechanical-thermal bonding,ultrasonic bonding, and combinations thereof. In particular, in apreferred embodiment, adhesive is applied by printing methods, such asgravure printing, reverse gravure printing, screen printing,flexographic printing, and the like. In one preferred embodiment, EVAhot melt adhesive may be screen printed in a lattice pattern generallyas shown in FIG. 1. The suitable screen for this embodiment is a 40 meshGalvano screen manufactured by Rothtec Engraving Corp., New Bedford,Mass.

[0086] The adhesive is preferably water insoluble so that the article 20can be wetted with water without delamination of the first and secondlayers. The adhesive is preferably also surfactant tolerant. By“surfactant tolerant” it is meant that the bonding characteristics ofthe adhesive are not degraded by the presence of surfactants. Suitableadhesives include EVA (ethylene vinyl acetate) based hot melt adhesives.One suitable adhesive is a hot melt adhesive commercially available asH1382-01 from Ato-Findley Adhesives of Wauwatosa, Wis.

[0087] With reference to FIGS. 1 and 2, the hot melt adhesive can beapplied to the nonwoven second layer 200 in a continuous networkdefining a discontinuous plurality of unbonded regions 114. In onepreferred embodiment, as shown in FIG. 1, the adhesive is applied asparallel, spaced apart lines in a first direction, intersected byparallel, spaced apart lines in a second direction. The intersectinglines form diamond-shaped patterns of unbonded regions in the finalwipe. In the embodiment shown in FIG. 1, the hot melt adhesive can beapplied in lines having a width of about 0.025 centimeter to about 1.25centimeter, preferably about 0.125 to about 0.18 centimeter. The spacingbetween adjacent lines of adhesive can be about 0.5 to 5.0 centimeter,preferably about 1.0 to 1.5 centimeter.

[0088] With reference to FIG. 3, the hot melt adhesive can be applied tothe nonwoven second layer 200 in bands which extend generally parallelto the machine direction of the nonwoven second layer 200. The hot meltadhesive can be applied in stripes 310 having a width W (FIG. 3) ofabout 0.32 centimeter to 2.54 centimeters. The spacing D betweenadjacent adhesive stripes can be about 0.32 centimeter to 5.1centimeters. In FIG. 3, four stripes 310A, 310B, 310C, and 310D areshown.

[0089] When applied as parallel stripes, lines, or bands, the adhesivecan be applied to the nonwoven second layer 200 using a slot coatingapplicator. A suitable slot coating applicator is a Nordson MX serieshot melter with extrusion head commercially available from the NordsonCompany of Norcross, Ga. The H1382-01 adhesive referenced above can beapplied to the second layer 200 at a temperature of about 350Fahrenheit, at an application level of about 0.03 grams of adhesive persquare inch. Immediately following application of the adhesive to thenonwoven second layer 200, the nonwoven second layer 200 and the paperfirst layer 100 can be bonded together by pressing the two layers 100and 200 together with the adhesive disposed between the second layer 200and the first layer 100. One suitable means for pressing the two layers100 and 200 together is by passing the two layers through a nip formedbetween two rollers, with the rollers loaded to provide adequate nippressure for bonding.

[0090] The resulting laminate of the first and second layers can have anaverage dry caliper of about 28.5 mils (0.072 centimeter), an averagewet caliper of about 32.1 mils (0.082 centimeter), and a wet caliper todry caliper ratio of about 1.1. The dry caliper, wet caliper, and wetcaliper to dry caliper ratio are measured as described below under “WetCaliper to Dry Caliper Ratio.”

[0091] Wet Extensiblity Test

[0092] The wet extensibility of a layer, such as the layer 100 or thelayer 200, is determined using the following procedure. Samples areconditioned at 70 degrees Fahrenheit and 50 percent relative humidityfor two hours prior to testing.

[0093] First, the direction of greatest wet extensibility in the planeof the layer is determined. For dry creped paper webs, this directionwill be parallel to the machine direction, and generally perpendicularto the crepe ridges.

[0094] If the direction of greatest wet extensibility is not known, thedirection can be determined by cutting seven samples from a sheet withsample lengths oriented between 0 degrees and 90 degrees, inclusive,with respect to a reference line drawn on the sheet. The samples arethen measured as set forth below to determine the direction of greatestwet extensibility.

[0095] Once the direction of the greatest wet extensibility isdetermined, 8 samples are cut to have a length of about 18 centimetersmeasured parallel to the direction of greatest wet extensibility, and awidth of at least 2.54 centimeters. The samples are cut from unbondedportions of the layers 100 and 200, or, if unbonded portions having theabove dimensions cannot be cut from the article 20, then samples are cutfrom the layers 100 and 200 prior to bonding the layers together. Twomarks are placed on each sample, such as with an ink pen. The marks arespaced apart 12.7 centimeters as measured parallel to the direction ofgreatest wet extensibility. This 12.7 centimeter length is the initialdry test length of the sample.

[0096] Each sample is thoroughly wetted by submerging the sample indistilled water for 30 seconds in a water bath. Each sample is removedfrom the water bath and immediately supported to hang vertically so thata line through the two marks is generally vertical. The wet sample issupported such that the support does not interfere with extensionbetween the two marks (e.g. with a clip which does not contact thesample between the two marks). The wet test length of the sample is thedistance between the two marks. The distance is measured within 30seconds of removing the sample from the water bath.

[0097] For each sample, the percent wet extension is calculated as

Sample Wet Extension=(wet test length−initial dry test length)/(initialdry test length)×100

[0098] For example, for a measured wet test length of 16.5 centimetersand an initial dry test length of 12.7 centimeters, the wet extension is((16.5−12.7)/12.7)×100=30 percent. The wet extensibility of the samplesis the average of 8 calculated values of sample wet extension.

[0099] In the preferred embodiment of the invention herein, the firstlayer preferably has a wet extensibility of at least about 4 percent,more preferably at least about 10 percent, and still more preferably atleast about 20 percent as measured using the “Wet Extensibility Test”provided hereinbefore. The first layer can be foreshortened to providethe desired wet extensibility. In one embodiment, the first layercomprises a wet laid, apertured paper web which is foreshortened about30 percent by dry creping. The second layer has a wet extensibility thatis less than that of the first layer. The wet extensibility of the firstlayer minus the wet extensibility of the second layer is preferably atleast about 4 percent, more preferably at least about 10 percent, andstill more preferably at least about 20 percent.

[0100] WET CALIPER TO DRY CALIPER RATIO

[0101] The wet caliper to dry caliper ratio is measured using aThwing-Albert Instrument Co. Electronic Thickness Tester Model II, usingthe following procedure. Samples are conditioned at 70 degreesFahrenheit and 50 percent relative humidity for two hours prior totesting.

[0102] The dry caliper of the article 20 is measured using a confiningpressure of 95 grams per square inch and a load foot having a diameterof 2 inches. The dry caliper is measured for eight samples. For eachsample, the caliper is measured with the load foot centered on anunbonded region of the first layer 100. The eight caliper measurementsare averaged to provide an average dry caliper.

[0103] Each sample is then wetted by submerging the sample in adistilled water bath for 30 seconds. The sample is then removed from thewater bath and drained by hanging vertically for about five seconds. Thecaliper of the wet sample is measured within 30 seconds of removing thesample from the bath. The wet caliper is measured in the same locationin which the dry caliper was previously measured. The eight wet calipermeasurements are averaged to provide an average wet caliper. The wetcaliper to dry caliper ratio is the average wet caliper divided by theaverage dry caliper.

[0104] The wet caliper to dry caliper ratio is the average wet caliperdivided by the average dry caliper.

[0105] In the preferred two-ply substrate herein, the disposablecleansing and conditioning article can have a wet caliper to dry caliperratio greater than 1.0, more preferably at least about 1.1, even morepreferably at least about 1.2, and most preferably at least about 1.4.

[0106] LATHERING SURFACTANT

[0107] Besides the water-insoluble substrate, the articles of thepresent invention also comprise one or more lathering surfactants whichare releasably associated with the water-insoluble substrate. Thus thelathering surfactants can be added onto or impregnated into thesubstrate. Generally this will be done prior to the point of use of thearticle, i.e., the surfactants will be combined with the article and thearticle dried before the article is ultimately wetted for use. Preferredarticles of the present invention comprise a sufficient amount of one ormore lathering surfactants such that the articles are capable ofgenerating≧30 ml of Lather Volume (medium hardness water at 95° C.)according to the Lather Volume Test described below.

[0108] Generally the articles will contain from about 0.5% to 250%, byweight of the substrate, of a lathering surfactant that is releasablyassociated with the substrate. Preferably, the articles of the presentinvention comprise from about 0.5% to about 12.5%, more preferably fromabout 0.75% to about 11%, and most preferably from about 1% to about10%, based on the weight of the water insoluble substrate, of alathering surfactant component.

[0109] By a lathering surfactant is meant a surfactant, which whencombined with water and mechanically agitated generates a foam or lathersufficient to cause the article, as a whole, to provide a lather.Preferably, these surfactants or combinations of surfactants should bemild, which means that these surfactants provide sufficient cleansing ordetersive benefits but do not overly dry the skin or hair, and yet meetthe lathering criteria described above.

[0110] A wide variety of lathering surfactants are useful herein andinclude those selected from the group consisting of anionic latheringsurfactants, nonionic lather surfactants, amphoteric latheringsurfactants, and mixtures thereof. Generally, the lathering surfactantsdo not strongly interfere with deposition of any conditioning agentsthat are present, e.g., are fairly water soluble, and usually have anHLB value of above 10. Cationic surfactants can also be used as optionalcomponents, provided they do not negatively impact the overall latheringcharacteristics of the required lathering surfactants.

[0111] Anionic Lathering Surfactants

[0112] Nonlimiting examples of anionic lathering surfactants useful inthe compositions of the present invention are disclosed in McCutcheon's,Detergents and Emulsifiers, North American edition (1986), published byallured Publishing Corporation; McCutcheon's, Functional Materials,North American Edition (1992); and U.S. Pat. No. 3,929,678, to Laughlinet al., issued Dec. 30, 1975, all of which are incorporated by referenceherein in their entirety.

[0113] A wide variety of anionic lathering surfactants are usefulherein. Nonlimiting examples of anionic lathering surfactants includethose selected from the group consisting of sarcosinates, sulfates,isethionates, taurates, phosphates, lactylates, glutamates, and mixturesthereof. Amongst the isethionates, the alkoyl isethionates arepreferred, and amongst the sulfates, the alkyl and alkyl ether sulfatesare preferred. The alkoyl isethionates typically have the formulaRCO—OCH₂CH₂SO₃M wherein R is alkyl or alkenyl of from about 10 to about30 carbon atoms, and M is a water-soluble cation such as ammonium,sodium, potassium and triethanolamine. Nonlimiting examples of theseisethionates include those alkoyl isethionates selected from the groupconsisting of ammonium cocoyl isethionate, sodium cocoyl isethionate,sodium lauroyl isethionate, and mixtures thereof.

[0114] The alkyl and alkyl ether sulfates typically have the respectiveformulas ROSO₃M and RO(C₂H₄O)_(x)SO₃M, wherein R is alkyl or alkenyl offrom about 10 to about 30 carbon atoms, x is from about 1 to about 10,and M is a water-soluble cation such as ammonium, sodium, potassium andtriethanolamine. Another suitable class of anionic surfactants are thewater-soluble salts of the organic, sulfuric acid reaction products ofthe general formula:

R1—SO₃—M

[0115] wherein R1 is chosen from the group consisting of a straight orbranched chain, saturated aliphatic hydrocarbon radical having fromabout 8 to about 24, preferably about 10 to about 16, carbon atoms; andM is a cation. Still other anionic synthetic surfactants include theclass designated as succinamates, olefin sulfonates having about 12 toabout 24 carbon atoms, and b-alkyloxy alkane sulfonates. Examples ofthese materials are sodium lauryl sulfate and ammonium lauryl sulfate.

[0116] Other anionic materials useful herein are soaps (i.e., alkalimetal salts, e.g., sodium or potassium salts) of fatty acids, typicallyhaving from about 8 to about 24 carbon atoms, preferably from about 10to about 20 carbon atoms. The fatty acids used in making the soaps canbe obtained from natural sources such as, for instance, plant oranimal-derived glycerides (e.g., palm oil, coconut oil, soybean oil,castor oil, tallow, lard, etc.) The fatty acids can also besynthetically prepared. Soaps are described in more detail in U.S. Pat.No. 4,557,853, cited above.

[0117] Other anionic materials include phosphates such as monoalkyl,dialkyl, and trialkylphosphate salts.

[0118] Other anionic materials include alkanoyl sarcosinatescorresponding to the formula RCON(CH₃)CH₂CH₂CO₂M wherein R is alkyl oralkenyl of about 10 to about 20 carbon atoms, and M is a water-solublecation such as ammonium, sodium, potassium and alkanolamine (e.g.,triethanolamine), a preferred examples of which are sodium lauroylsarcosinate, sodium cocoyl sarcosinate, ammonium lauroyl sarcosinate,and sodium myristoyl sarcosinate. TEA salts of sarcosinates are alsouseful.

[0119] Also useful are taurates which are based on taurine, which isalso known as 2-aminoethanesulfonic acid. Especially useful are taurateshaving carbon chains between C₈ and C₁₆. Examples of taurates includeN-alkyltaurines such as the one prepared by reacting dodecylamine withsodium isethionate according to the teaching of U.S. Pat. No. 2,658,072which is incorporated herein by reference in its entirety. Furthernonlimiting examples include ammonium, sodium, potassium andalkanolamine (e.g., triethanolamine) salts of lauroyl methyl taurate,myristoyl methyl taurate, and cocoyl methyl taurate.

[0120] Also useful are lactylates, especially those having carbon chainsbetween C₈ and C₁₆. Nonlimiting examples of lactylates include ammonium,sodium, potassium and alkanolamine (e.g., triethanolamine) salts oflauroyl lactylate, cocoyl lactylate, lauroyl lactylate, and caproyllactylate.

[0121] Also useful herein as anionic surfactants are glutamates,especially those having carbon chains between C₈ and C₁₆. Nonlimitingexamples of glutamates include ammonium, sodium, potassium andalkanolamine (e.g., triethanolamine) salts of lauroyl glutamate,myristoyl glutamate, and cocoyl glutamate.

[0122] Nonlimiting examples of preferred anionic lathering surfactantsuseful herein include those selected from the group consisting of sodiumlauryl sulfate, ammonium lauryl sulfate, ammonium laureth sulfate,sodium laureth sulfate, sodium trideceth sulfate, ammonium cetylsulfate, sodium cetyl sulfate, ammonium cocoyl isethionate, sodiumlauroyl isethionate, sodium lauroyl lactylate, triethanolamine lauroyllactylate, sodium caproyl lactylate, sodium lauroyl sarcosinate, sodiummyristoyl sarcosinate, sodium cocoyl sarcosinate, sodium lauroyl methyltaurate, sodium cocoyl methyl taurate, sodium lauroyl glutamate, sodiummyristoyl glutamate, and sodium cocoyl glutamate and mixtures thereof.

[0123] Especially preferred for use herein is ammonium lauryl sulfate,ammonium laureth sulfate, sodium lauroyl sarcosinate, sodium cocoylsarcosinate, sodium myristoyl sarcosinate, sodium lauroyl lactylate, andtriethanolamine lauroyl lactylate.

[0124] Nonionic Lathering Surfactants

[0125] Nonlimiting examples of nonionic lathering surfactants for use inthe compositions of the present invention are disclosed in McCutcheon's,Detergents and Emulsifiers, North American edition (1986), published byallured Publishing Corporation; and McCutcheon's, Functional Materials,North American Edition (1992); both of which are incorporated byreference herein in their entirety.

[0126] Nonionic lathering surfactants useful herein include thoseselected from the group consisting of alkyl glucosides, alkylpolyglucosides, polyhydroxy fatty acid amides, alkoxylated fatty acidesters, lathering sucrose esters, amine oxides, and mixtures thereof.

[0127] Alkyl glucosides and alkyl polyglucosides are useful herein, andcan be broadly defined as condensation articles of long chain alcohols,e.g. C₈₋₃₀ alcohols, with sugars or starches or sugar or starchpolymers, i.e., glycosides or polyglycosides. These compounds can berepresented by the formula (S)_(n)—O—R wherein S is a sugar moiety suchas glucose, fructose, mannose, and galactose; n is an integer of fromabout 1 to about 1000, and R is a C₈₋₃₀ alkyl group. Examples of longchain alcohols from which the alkyl group can be derived include decylalcohol, cetyl alcohol, stearyl alcohol, lauryl alcohol, myristylalcohol, oleyl alcohol, and the like. Preferred examples of thesesurfactants include those wherein S is a glucose moiety, R is a C₈₋₂₀alkyl group, and n is an integer of from about 1 to about 9.Commercially available examples of these surfactants include decylpolyglucoside (available as APG 325 CS from Henkel) and laurylpolyglucoside (available as APG 600CS and 625 CS from Henkel). Alsouseful are sucrose ester surfactants such as sucrose cocoate and sucroselaurate.

[0128] Other useful nonionic surfactants include polyhydroxy fatty acidamide surfactants, more specific examples of which include glucosamides,corresponding to the structural formula:

[0129] wherein: R¹ is H, C₁-C₄ alkyl, 2-hydroxyethyl, 2-hydroxy-propyl,preferably C₁-C₄ alkyl, more preferably methyl or ethyl, most preferablymethyl; R² is C₅-C₃₁ alkyl or alkenyl, preferably C₇-C₁₉ alkyl oralkenyl, more preferably C₉-C₁₇ alkyl or alkenyl, most preferablyC₁₁-C₁₅ alkyl or alkenyl; and Z is a polhydroxyhydrocarbyl moiety havinga linear hydrocarbyl chain with a least 3 hydroxyls directly connectedto the chain, or an alkoxylated derivative (preferably ethoxylated orpropoxylated) thereof. Z preferably is a sugar moiety selected from thegroup consisting of glucose, fructose, maltose, lactose, galactose,mannose, xylose, and mixtures thereof. An especially preferredsurfactant corresponding to the above structure is coconut alkylN-methyl glucoside amide (i.e., wherein the R²CO— moiety is derived fromcoconut oil fatty acids). Processes for making compositions containingpolyhydroxy fatty acid amides are disclosed, for example, in G.B. PatentSpecification 809,060, published Feb. 18, 1959, by Thomas Hedley & Co.,Ltd.; U.S. Pat. No. 2,965,576, to E. R. Wilson, issued Dec. 20, 1960;U.S. Pat. No. 2,703,798, to A. M. Schwartz, issued Mar. 8, 1955; andU.S. Pat. No. 1,985,424, to Piggott, issued Dec. 25, 1934; which areincorporated herein by reference in their entirety.

[0130] Other examples of nonionic surfactants include amine oxides.Amine oxides correspond to the general formula R¹R²R³NO, wherein R¹contains an alkyl, alkenyl or monohydroxy alkyl radical of from about 8to about 18 carbon atoms, from 0 to about 10 ethylene oxide moieties,and from 0 to about 1 glyceryl moiety, and R² and R³ contain from about1 to about 3 carbon atoms and from 0 to about 1 hydroxy group, e.g.,methyl, ethyl, propyl, hydroxyethyl, or hydroxypropyl radicals. Thearrow in the formula is a conventional representation of a semipolarbond. Examples of amine oxides suitable for use in this inventioninclude dimethyl-dodecylamine oxide, oleyldi(2-hydroxyethyl) amineoxide, dimethyloctylamine oxide, dimethyl-decylamine oxide,dimethyl-tetradecylamine oxide, 3,6,9-trioxaheptadecyldiethylamineoxide, di(2-hydroxyethyl)-tetradecylamine oxide,2-dodecoxyethyldimethylamine oxide,3-dodecoxy-2-hydroxypropyldi(3-hydroxypropyl)amine oxide,dimethylhexadecylamine oxide.

[0131] Nonlimiting examples of preferred nonionic surfactants for useherein are those selected form the group consisting of C₈-C₁₄ glucoseamides, C₈-C₁₄ alkyl polyglucosides, sucrose cocoate, sucrose laurate,lauramine oxide, cocoamine oxide, and mixtures thereof.

[0132] Amphoteric Lathering Surfactants

[0133] The term “amphoteric lathering surfactant,” as used herein, isalso intended to encompass zwitterionic surfactants, which are wellknown to formulators skilled in the art as a subset of amphotericsurfactants.

[0134] A wide variety of amphoteric lathering surfactants can be used inthe compositions of the present invention. Particularly useful are thosewhich are broadly described as derivatives of aliphatic secondary andtertiary amines, preferably wherein the nitrogen is in a cationic state,in which the aliphatic radicals can be straight or branched chain andwherein one of the radicals contains an ionizable water solubilizinggroup, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate.

[0135] Nonlimiting examples of amphoteric surfactants useful in thecompositions of the present invention are disclosed in McCutcheon's,Detergents and Emulsifiers, North American edition (1986), published byallured Publishing Corporation; and McCutcheon's, Functional Materials,North American Edition (1992); both of which are incorporated byreference herein in their entirety.

[0136] Nonlimiting examples of amphoteric or zwitterionic surfactantsare those selected from the group consisting of betaines, sultaines,hydroxysultaines, alkyliminoacetates, iminodialkanoates,aminoalkanoates, and mixtures thereof.

[0137] Examples of betaines include the higher alkyl betaines, such ascoco dimethyl carboxymethyl betaine, lauryl dimethyl carboxymethylbetaine, lauryl dimethyl alphacarboxyethyl betaine, cetyl dimethylcarboxymethyl betaine, cetyl dimethyl betaine (available as Lonzaine16SP from Lonza Corp.), lauryl bis-(2-hydroxyethyl) carboxymethylbetaine, oleyl dimethyl gamma-carboxypropyl betaine, laurylbis-(2-hydroxypropyl)alpha-carboxyethyl betaine, coco dimethylsulfopropyl betaine, lauryl dimethyl sulfoethyl betaine, laurylbis-(2-hydroxyethyl) sulfopropyl betaine, amidobetaines andamidosulfobetaines (wherein the RCONH(CH₂)₃ radical is attached to thenitrogen atom of the betaine), oleyl betaine (available as amphotericVelvetex OLB-50 from Henkel), and cocamidopropyl betaine (available asVelvetex BK-35 and BA-35 from Henkel).

[0138] Examples of sultaines and hydroxysultaines include materials suchas cocamidopropyl hydroxysultaine (available as Mirataine CBS fromRhone-Poulenc).

[0139] Preferred for use herein are amphoteric surfactants having thefollowing structure:

[0140] wherein R¹ is unsubstituted, saturated or unsaturated, straightor branched chain alkyl having from about 9 to about 22 carbon atoms.Preferred R¹ has from about 11 to about 18 carbon atoms; more preferablyfrom about 12 to about 18 carbon atoms; more preferably still from about14 to about 18 carbon atoms; m is an integer from 1 to about 3, morepreferably from about 2 to about 3, and more preferably about 3; n iseither 0 or 1, preferably 1; R² and R³ are independently selected fromthe group consisting of alkyl having from 1 to about 3 carbon atoms,unsubstituted or mono-substituted with hydroxy, preferred R² and R³ areCH₃; X is selected from the group consisting of CO₂, SO₃ and SO₄; R⁴ isselected from the group consisting of saturated or unsaturated, straightor branched chain alkyl, unsubstituted or monosubstituted with hydroxy,having from 1 to about 5 carbon atoms. When X is CO₂, R⁴ preferably has1 or 3 carbon atoms, more preferably 1 carbon atom. When X is SO₃ orSO₄, R⁴ preferably has from about 2 to about 4 carbon atoms, morepreferably 3 carbon atoms.

[0141] Examples of amphoteric surfactants of the present inventioninclude the following compounds:

[0142] Cetyl dimethyl betaine (this material also has the CTFAdesignation cetyl betaine)

[0143] Cocamidopropylbetaine

[0144] wherein R has from about 9 to about 13 carbon atoms

[0145] Cocamidopropyl hydroxy sultaine

[0146] wherein R has from about 9 to about 13 carbon atoms,

[0147] Examples of other useful amphoteric surfactants arealkyliminoacetates, and iminodialkanoates and aminoalkanoates of theformulas RN[CH₂)_(m)CO₂M]₂ and RNH(CH₂)_(m)CO₂M wherein m is from 1 to4, R is a C₈-C₂₂ alkyl or alkenyl, and M is H, alkali metal, alkalineearth metal ammonium, or alkanolammonium. Also included areimidazolinium and ammonium derivatives. Specific examples of suitableamphoteric surfactants include sodium 3-dodecyl-aminopropionate, sodium3-dodecylaminopropane sulfonate, N-higher alkyl aspartic acids such asthose produced according to the teaching of U.S. Pat. No. 2,438,091which is incorporated herein by reference in its entirety; and theproducts sold under the trade name “Miranol” and described in U.S. Pat.No. 2,528,378, which is incorporated herein by reference in itsentirety. Other examples of useful amphoterics include amphotericphosphates, such as coamidopropyl PG-dimonium chloride phosphate(commercially available as Monaquat PTC, from Mona Corp.). Also usefulare amphoacetates such as disodium lauroamphodiacetate, sodiumlauroamphoacetate, and mixtures thereof.

[0148] Preferred lathering surfactants for use herein are the following,wherein the anionic lathering surfactant is selected from the groupconsisting of ammonium lauroyl sarcosinate, sodium trideceth sulfate,sodium lauroyl sarcosinate, ammonium laureth sulfate, sodium laurethsulfate, ammonium lauryl sulfate, sodium lauryl sulfate, ammonium cocoylisethionate, sodium cocoyl isethionate, sodium lauroyl isethionate,sodium cetyl sulfate, sodium lauroyl lactylate, triethanolamine lauroyllactylate, and mixtures thereof; wherein the nonionic latheringsurfactant is selected from the group consisting of lauramine oxide,cocoamine oxide, decyl polyglucose, lauryl polyglucose, sucrose cocoate,C₁₂₋₁₄ glucosamides, sucrose laurate, and mixtures thereof; and whereinthe amphoteric lathering surfactant is selected from the groupconsisting of disodium lauroamphodiacetate, sodium lauroamphoacetate,cetyl dimethyl betaine, cocoamidopropyl betaine, cocoamidopropyl hydroxysultaine, and mixtures thereof.

[0149] Lather Volume Test

[0150] The articles of the present invention preferably comprise enoughof the lathering surfactant such that the articles are capable ofgenerating greater than or equal to about 30 ml, more preferably greaterthan or equal to about 50 ml, even more preferably greater than or equalto about 75 ml, and most preferably greater than or equal to about 150ml of Average Lather Volume. The Average Lather Volume is a measurementdetermined by the Lather Volume Test. This test provides a consistentmeasurement of the volume of lather/foam generated by the articlesdescribed herein. The Lather Volume Test protocol is described asfollows:

[0151] (1) Hands are washed with Ivory bar before conducting the test.This step removes any soils which may affect the accuracy of themeasurement.

[0152] (2) The test article is held open in the non-dominant hand withthe edges turned up. (3) 10 m. of water (medium hardness of about 8-10grains per gallon) at 95° C. is added onto the test article via a 10 ccsyringe or a Brinkmann repipetter.

[0153] (4) The lather is then generated by rubbing the test article withthe dominant hand in a circular motion between the palms for 6 seconds(˜2 rotations per second), using moderate pressure (e.g., 4 oz.), andallowing the article to ball-up between the palms of the hand.

[0154] (5) The test article is then held open in the non-dominant handand an additional 10 ml of water (medium hardness of about 8-10 grainsper gallon) at 95° C. is added onto the test article via a 10 cc syringeor a Brinkmann repipetter. The wetted article is again rubbed with thedominant had (3 rotations) using moderate force (e.g, 4 oz.) so that thetest article becomes balled-up between the palms.

[0155] (6) The test article is then opened and rubbed 5 times by holdingone edge of the article in one hand and rotating the hand holding theother side to further activate lather.

[0156] (7) The test article is then flipped over and Step#6 is repeatedusing the other hand.

[0157] (8) The lather is gathered by holding the test article in acupped hand and scraping the lather off the test article with the otherhand, being careful to only scrape lather from the test article. Thelather from the test article is placed into a graduated cylinder orbeaker big enough to hold the generated lather. This procedure isrepeated 5 times on the same test article, and the lather from eachiteration is accumulated in the same graduated cylinder or beaker. Thetotal accumulated lather from these iterations is designated as theLather Volume.

[0158] (9) To achieve consistent results, the Average Lather Volume isreported as the average of three test sample replications of Steps 1-8.

[0159] CONDITIONING COMPONENT

[0160] The articles of the present invention will preferably furthercomprise a conditioning component which is useful for providing aconditioning benefit to the skin or hair during the use of the article.The conditioning component can comprise from about 0.05% to about 99%,preferably from about 0.1% to about 50%, and more preferably from about1% to about 25% by weight of said water insoluble substrate.

[0161] The conditioning component useful in the present invention cancomprise: a water soluble conditioning agent; an oil solubleconditioning agent; a conditioning emulsion; or any combination orpermutation of the three. The oil soluble conditioning agent is selectedfrom one or more oil soluble conditioning agents such that the weightedarithmetic mean solubility parameter of the oil soluble conditioningagent is less than or equal to 10.5. The water soluble conditioningagent is selected from one or more water soluble conditioning agentssuch that the weighted arithmetic mean solubility parameter of the watersoluble conditioning agent is greater than 10.5. It is recognized, basedon this mathematical definition of solubility parameters, that it ispossible, for example, to achieve the required weighted arithmetic meansolubility parameter, i.e. less than or equal to 10.5, for an oilsoluble conditioning agent comprising two or more compounds if one ofthe compounds has an individual solubility parameter greater than 10.5.Conversely, it is possible to achieve the appropriate weightedarithmetic mean solubility parameter, i.e. greater than 10.5, for awater soluble conditioning agent comprising two or more compounds if oneof the compounds has an individual solubility parameter less than orequal to 10.5.

[0162] Solubility parameters are well known to the formulation chemistof ordinary skill in the art and are routinely used as a guide fordetermining compatibilities and solubilities of materials in theformulation process.

[0163] The solubility parameter of a chemical compound, δ, is defined asthe square root of the cohesive energy density for that compound.Typically, a solubility parameter for a compound is calculated fromtabulated values of the additive group contributions for the heat ofvaporization and molar volume of the components of that compound, usingthe following equation:$\delta = \left\lbrack \frac{\sum\limits_{i}E_{i}}{\sum\limits_{i}m_{i}} \right\rbrack^{1/2}$

[0164] wherein Σ_(i) E_(i)=the sum of the heat of vaporization additivegroup contributions, and Σ_(i) m_(i)=the sum of the molar volumeadditive group contributions

[0165] Standard tabulations of heat of vaporization and molar volumeadditive group contributions for a wide variety of atoms and groups ofatoms are collected in Barton, A.F.M. Handbook of Solubility Parameters,CRC Press, Chapter 6, Table 3, pp. 64-66 (1985), which is incorporatedby reference herein in its entirety. The above solubility parameterequation is described in Fedors, R. F., “A Method for Estimating Boththe Solubility Parameters and Molar Volumes of Liquids”, PolymerEngineering and Science, vol. 14, no. 2, pp. 147-154 (February 1974),which is incorporated by reference herein in its entirety.

[0166] Solubility parameters obey the law of mixtures such that thesolubility parameter for a mixture of materials is given by the weightedarithmetic mean (i.e. the weighted average) of the solubility parametersfor each component of that mixture. See, Handbook of Chemistry andPhysics, 57th edition, CRC Press, p. C-726 (1976-1977), which isincorporated by reference herein in its entirety.

[0167] Formulation chemists typically report and use solubilityparameters in units of (cal/cm³)^(½). The tabulated values of additivegroup contributions for heat of vaporization in the Handbook ofSolubility Parameters are reported in units of kJ/mol. However, thesetabulated heat of vaporization values are readily converted to cal/molusing the following well-known relationships:

1 J/mol=0.239006 cal/mol and 1000 J=1 kJ.

[0168] See Gordon, A. J. et al., The Chemist's Companion, John Wiley &Sons, pp. 456-463, (1972), which is incorporated by reference herein inits entirety.

[0169] Solubility parameters have also been tabulated for a wide varietyof chemical materials. Tabulations of solubility parameters are found inthe above-cited Handbook of Solubility Parameters. Also, see “SolubilityEffects In Product, Package, Penetration, And Preservation”, C. D.Vaughan, Cosmetics and Toiletries, vol. 103, October 1988, pp.47-69,which is incorporated by reference herein in its entirety.

[0170] Nonlimiting examples of conditioning agents useful as oil solubleconditioning agents include those selected from the group consisting ofmineral oil, petrolatum, C₇-C₄₀ branched chain hydrocarbons, C₁-C₃₀alcohol esters of C₁-C₃₀ carboxylic acids, C₁-C₃₀ alcohol esters ofC₂-C₃₀ dicarboxylic acids, monoglycerides of C₁-C₃₀ carboxylic acids,diglycerides of C₁-C₃₀ carboxylic acids, triglycerides of C₁-C₃₀carboxylic acids, ethylene glycol monoesters of C₁-C₃₀ carboxylic acids,ethylene glycol diesters of C₁-C₃₀ carboxylic acids, propylene glycolmonoesters of C₁-C₃₀ carboxylic acids, propylene glycol diesters ofC₁-C₃₀ carboxylic acids, C₁-C₃₀ carboxylic acid monoesters andpolyesters of sugars, polydialkylsiloxanes, polydiarylsiloxanes,polyalkarylsiloxanes, cylcomethicones having 3 to 9 silicon atoms,vegetable oils, hydrogenated vegetable oils, polypropylene glycol C₄-C₂₀alkyl ethers, di C₈-C₃₀ alkyl ethers, and mixtures thereof.

[0171] Mineral oil, which is also known as petrolatum liquid, is amixture of liquid hydrocarbons obtained from petroleum. See The MerckIndex, Tenth Edition, Entry 7048, p. 1033 (1983) and InternationalCosmetic Ingredient Dictionary, Fifth Edition, vol. 1, p.415-417 (1993),which are incorporated by reference herein in their entirety.

[0172] Petrolatum, which is also known as petroleum jelly, is acolloidal system of nonstraight-chain solid hydrocarbons andhigh-boiling liquid hydrocarbons, in which most of the liquidhydrocarbons are held inside the micelles. See The Merck Index, TenthEdition, Entry 7047, p. 1033 (1983); Schindler, Drug. Cosmet. Ind., 89,36-37, 76, 78-80, 82 (1961); and International Cosmetic IngredientDictionary, Fifth Edition, vol. 1, p. 537 (1993), which are incorporatedby reference herein in their entirety.

[0173] Straight and branched chain hydrocarbons having from about 7 toabout 40 carbon atoms are useful herein. Nonlimiting examples of thesehydrocarbon materials include dodecane, isododecane, squalane,cholesterol, hydrogenated polyisobutylene, docosane (i.e. a C₂₂hydrocarbon), hexadecane, isohexadecane (a commercially availablehydrocarbon sold as Permethyl® 101A by Presperse, South Plainfield,N.J.). Also useful are the C₇-C₄₀ isoparaffins, which are C₇-C₄₀branched hydrocarbons.

[0174] Also useful are C₁-C₃₀ alcohol esters of C₁-C₃₀ carboxylic acidsand of C₂-C₃₀ dicarboxylic acids, including straight and branched chainmaterials as well as aromatic derivatives. Also useful are esters suchas monoglycerides of C₁-C₃₀ carboxylic acids, diglycerides of C₁-C₃₀carboxylic acids, triglycerides of C₁-C₃₀ carboxylic acids, ethyleneglycol monoesters of C₁-C₃₀ carboxylic acids, ethylene glycol diestersof C₁-C₃₀ carboxylic acids, propylene glycol monoesters of C₁-C₃₀carboxylic acids, and propylene glycol diesters of C₁-C₃₀ carboxylicacids. Straight chain, branched chain and aryl carboxylic acids areincluded herein. Also useful are propoxylated and ethoxylatedderivatives of these materials. Nonlimiting examples include diisopropylsebacate, diisopropyl adipate, isopropyl myristate, isopropyl palmitate,myristyl propionate, ethylene glycol distearate, 2-ethylhexyl palmitate,isodecyl neopentanoate, di-2-ethylhexyl maleate, cetyl palmitate,myristyl myristate, stearyl stearate, cetyl stearate, behenyl behenrate,dioctyl maleate, dioctyl sebacate, diisopropyl adipate, cetyl octanoate,diisopropyl dilinoleate, caprilic/capric triglyceride, PEG-6caprylic/capric triglyceride, PEG-8 caprylic/capric triglyceride, andmixtures thereof.

[0175] Also useful are various C₁-C₃₀ monoesters and polyesters ofglycerin and related materials. These esters are derived from glycerinand one or more carboxylic acid moieties. Depending on the constituentacid and glycerin, these esters can be in either liquid or solid form atroom temperature. Nonlimiting examples of solid esters include: glyceryltribehenate, glyceryl stearate, glyceryl palmitate, glyceryl distearate,glyceryl dipalmitate.

[0176] Also useful are various C₁-C₃₀ monoesters and polyesters ofsugars and related materials. These esters are derived from a sugar orpolyol moiety and one or more carboxylic acid moities. Depending on theconstituent acid and sugar, these esters can be in either liquid orsolid form at room temperature. Examples of liquid esters include:glucose tetraoleate, the glucose tetraesters of soybean oil fatty acids(unsaturated), the mannose tetraesters of mixed soybean oil fatty acids,the galactose tetraesters of oleic acid, the arabinose tetraesters oflinoleic acid, xylose tetralinoleate, galactose pentaoleate, sorbitoltetraoleate, the sorbitol hexaesters of unsaturated soybean oil fattyacids, xylitol pentaoleate, sucrose tetraoleate, sucrose pentaoleate,sucrose hexaoleate, sucrose hepatoleate, sucrose octaoleate, andmixtures thereof. Examples of solid esters include: sorbitol hexaesterin which the carboxylic acid ester moieties are palmitoleate andarachidate in a 1:2 molar ratio; the octaester of raffinose in which thecarboxylic acid ester moieties are linoleate and behenate in a 1:3 molarratio; the heptaester of maltose wherein the esterifying carboxylic acidmoieties are sunflower seed oil fatty acids and lignocerate in a 3:4molar ratio; the octaester of sucrose wherein the esterifying carboxylicacid moieties are oleate and behenate in a 2:6 molar ratio; and theoctaester of sucrose wherein the esterifying carboxylic acid moietiesare laurate, linoleate and behenate in a 1:3:4 molar ratio. A preferredsolid material is sucrose polyester in which the degree ofesterification is 7-8, and in which the fatty acid moieties are C₁₈mono- and/or di-unsaturated and behenic, in a molar ratio ofunsaturates:behenic of 1:7 to 3:5. A particularly preferred solid sugarpolyester is the octaester of sucrose in which there are about 7 behenicfatty acid moieties and about 1 oleic acid moiety in the molecule. Othermaterials include cottonseed oil or soybean oil fatty acid esters ofsucrose. The ester materials are further described in, U.S. Pat. No.2,831,854, U.S. Pat. No. 4,005,196, to Jandacek, issued Jan. 25, 1977;U.S. Pat. No. 4,005,195, to Jandacek, issued Jan. 25, 1977, U.S. Pat.No. 5,306,516, to Letton et al., issued Apr. 26, 1994; U.S. Pat. No.5,306,515, to Letton et al., issued Apr. 26, 1994; U.S. Pat. No.5,305,514, to Letton et al., issued Apr. 26, 1994; U.S. Pat. No.4,797,300, to Jandacek et al., issued Jan. 10, 1989; U.S. Pat. No.3,963,699, to Rizzi et al, issued Jun. 15, 1976; U.S. Pat. No.4,518,772, to Volpenhein, issued May 21, 1985; and U.S. Pat. No.4,517,360, to Volpenhein, issued May 21, 1985; all of which areincorporated by reference herein in their entirety.

[0177] Nonvolatile silicones such as polydialkylsiloxanes,polydiarylsiloxanes, and polyalkarylsiloxanes are also useful oils.These silicones are disclosed in U.S. Pat. No. 5,069,897, to Orr, issuedDec. 3, 1991, which is incorporated by reference herein in its entirety.The polyalkylsiloxanes correspond to the general chemical formulaR³SiO[R²SiO]_(x)SiR³ wherein R is an alkyl group (preferably R is methylor ethyl, more preferably methyl) and x is an integer up to about 500,chosen to achieve the desired molecular weight. Commercially availablepolyalkylsiloxanes include the polydimethylsiloxanes, which are alsoknown as dimethicones, nonlimiting examples of which include theVicasil® series sold by General Electric Company and the Dow Corning®200 series sold by Dow Corning Corporation. Specific examples ofpolydimethylsiloxanes useful herein include Dow Corning® 225 fluidhaving a viscosity of 10 centistokes and a boiling point greater than200° C., and Dow Corning® 200 fluids having viscosities of 50, 350, and12,500 centistokes, respectively, and boiling points greater than 200°C. Also useful are materials such as trimethylsiloxysilicate, which is apolymeric material corresponding to the general chemicalformula[(CH₂)₃SiO_(½)]_(x)[SiO₂]_(y), wherein x is an integer from about1 to about 500 and y is an integer from about 1 to about 500. Acommercially available trimethylsiloxysilicate is sold as a mixture withdimethicone as Dow Corning® 593 fluid. Also useful herein aredimethiconols, which are hydroxy terminated dimethyl silicones. Thesematerials can be represented by the general chemical formulasR³SiO[R²SiO]_(x)SiR²OH and HOR²SiO[R²SiO]_(x)SiR²OH wherein R is analkyl group (preferably R is methyl or ethyl, more preferably methyl)and x is an integer up to about 500, chosen to achieve the desiredmolecular weight. Commercially available dimethiconols are typicallysold as mixtures with dimethicone or cyclomethicone (e.g. Dow Corning®1401, 1402, and 1403 fluids). Also useful herein are polyalkylarylsiloxanes, with polymethylphenyl siloxanes having viscosities from about15 to about 65 centistokes at 25° C. being preferred. These materialsare available, for example, as SF 1075 methylphenyl fluid (sold byGeneral Electric Company) and 556 Cosmetic Grade phenyl trimethiconefluid (sold by Dow Coming Corporation).

[0178] Vegetable oils and hydrogenated vegetable oils are also usefulherein. Examples of vegetable oils and hydrogenated vegetable oilsinclude safflower oil, castor oil, coconut oil, cottonseed oil, menhadenoil, palm kernel oil, palm oil, peanut oil, soybean oil, rapeseed oil,linseed oil, rice bran oil, pine oil, sesame oil, sunflower seed oil,hydrogenated safflower oil, hydrogenated castor oil, hydrogenatedcoconut oil, hydrogenated cottonseed oil, hydrogenated menhaden oil,hydrogenated palm kernel oil, hydrogenated palm oil, hydrogenated peanutoil, hydrogenated soybean oil, hydrogenated rapeseed oil, hydrogenatedlinseed oil, hydrogenated rice bran oil, hydrogenated sesame oil,hydrogenated sunflower seed oil, and mixtures thereof.

[0179] Also useful are C₄-C₂₀ alkyl ethers of polypropylene glycols,C₁-C₂₀ carboxylic acid esters of polypropylene glycols, and di-C₈-C₃₀alkyl ethers. Nonlimiting examples of these materials include PPG-14butyl ether, PPG-15 stearyl ether, dioctyl ether, dodecyl octyl ether,and mixtures thereof.

[0180] Nonlimiting examples of conditioning agents useful as watersoluble conditioning agents include those selected from the groupconsisting of polyhydric alcohols, polypropylene glycols, polyethyleneglycols, ureas, pyrolidone carboxylic acids, ethoxylated and/orpropoxylated C₃-C₆ diols and triols, alpha-hydroxy C₂-C₆ carboxylicacids, ethoxylated and/or propoxylated sugars, polyacrylic acidcopolymers, sugars having up to about 12 carbons atoms, sugar alcoholshaving up to about 12 carbon atoms, and mixtures thereof. Specificexamples of useful water soluble conditioning agents include materialssuch as urea; guanidine; glycolic acid and glycolate salts (e.g.ammonium and quaternary alkyl ammonium); lactic acid and lactate salts(e.g. ammonium and quaternary alkyl ammonium); sucrose, fructose,glucose, eruthrose, erythritol, sorbitol, mannitol, glycerol,hexanetriol, propylene glycol, butylene glycol, hexylene glycol, and thelike; polyethylene glycols such as PEG-2, PEG-3, PEG-30, PEG-50,polypropylene glycols such as PPG-9, PPG-12, PPG-15, PPG-17, PPG-20,PPG-26, PPG-30, PPG-34; alkoxylated glucose; hyaluronic acid; andmixtures thereof. Also useful are materials such as aloe vera in any ofits variety of forms (e.g., aloe vera gel), chitin, starch-graftedsodium polyacrylates such as Sanwet (RTM) IM-1000, IM-1500, and IM-2500(available from Celanese Superabsorbent Materials, Portsmouth, Va.);lactamide monoethanolamine; acetamide monoethanolamine; and mixturesthereof. Also useful are propoxylated glycerols as described in U.S.Pat. No. 4,976,953, to Orr et al., issued Dec. 11, 1990, which isincorporated by reference herein in its entirety.

[0181] The conditioning component preferably used in the presentinvention may also comprise a conditioning emulsion which is useful forproviding a conditioning benefit to the skin or hair during the use ofthe article. The term “conditioning emulsion” as used herein means thecombination of an internal phase comprising a water soluble conditioningagent that is enveloped by an external phase comprising an oil solubleagent. In preferred embodiments, the conditioning emulsion would furthercomprise an emulsifier. The conditioning emulsion comprises from about0.25% to about 150%, preferably from about 0.5% to about 100%, and morepreferably from about 1% to about 50% by weight of said water insolublesubstrate. By a conditioning emulsion is meant a combination of aninternal phase comprising a water soluble conditioning agent that isenveloped by an external phase comprising an oil soluble agent. Inpreferred embodiments, the conditioning emulsion would further comprisean emulsifier.

[0182] The conditioning emulsion comprises (i) an internal phasecomprising water soluble conditioning agents as described above, and(ii) an external phase comprising oil soluble agents as describedhereinbefore in the oil soluble conditioning agent section orhereinafter in the “Materials Used to Increase Lipid Hardness Value”section. In further embodiments, the conditioning emulsion furthercomprises an emulsifier capable of forming an emulsion of said internaland external phases. Although an emulsifier capable of forming anemulsion of the internal and external phases is preferred in the presentinvention, it is recognized in the art of skin care formulations that awater soluble conditioning agent can be enveloped by an oil solubleagent without an emulsifier. As long as the water soluble conditioningagent is enveloped by the oil soluble agent, thereby protected frombeing rinsed away during the cleansing process, the composition would bewithin the scope of the present invention.

[0183] The internal phase can optionally comprise other water-soluble ordispersible materials that do not adversely affect the stability of theconditioning emulsion. One such material is a water-soluble electrolyte.The dissolved electrolyte minimizes the tendency of materials present inthe lipid phase to also dissolve in the water phase. Any electrolytecapable of imparting ionic strength to the internal phase can be used.Suitable electrolytes include the water soluble mono-, di- or trivalentinorganic salts such as water-soluble halides, e.g., chlorides, nitratesand sulfates of alkali metals and alkaline earth metals. Examples ofsuch electrolytes include sodium chloride, calcium chloride, sodiumsulfate, magnesium sulfate, and sodium bicarbonate. The electrolyte willtypically be included in a concentration in the range of from about 1 toabout 20% of the internal phase.

[0184] Other water-soluble or dispersible materials that can be presentin the internal phase include thickeners and viscosity modifiers.Suitable thickeners and viscosity modifiers include water-solublepolyacrylic and hydrophobically modified polyacrylic resins such asCarbopol and Pemulen, starches such as corn starch, potato starch,tapioca, gums such as guar gum, gum arabic, cellulose ethers such ashydroxypropyl cellulose, hydroxyethyl cellulose, carboxymethylcellulose, and the like. These thickeners and viscosity modifiers willtypically be included in a concentration in the range of from about 0.05to about 0.5% of the internal phase.

[0185] Other water soluble or dispersible materials that can be presentin the internal water phase include polycationic polymers to providesteric stabilization at the water-lipid interface and nonionic polymersthat also stabilize the water-in-lipid-emulsion. Suitable polycationicpolymers include Reten 201, Kymene 557H® and Acco 7112. Suitablenonionic polymers include polyethylene glycols (PEG) such as Carbowax.These polycationic and nonionic polymers will typically be included in aconcentration in the range of from about 0.1 to about 1.0% of theinternal phase.

[0186] Preferred embodiments of the present invention which containconditioning emulsions comprise an emulsifier capable of forming anemulsion of the internal and external phases. In the emulsions of thepresent invention, the emulsifier is included in an effective amount.What constitutes an “effective amount” will depend on a number offactors including the respective amounts of the oil soluble agents, thetype of emulsifier used, the level of impurities present in theemulsifier, and like factors. Typically, the emulsifier comprises fromabout 0.1% to about 20%, preferably from about 1% to about 10%, and morepreferably from about 3% to about 6% by weight of the conditioningemulsion.

[0187] The emulsifiers useful in the present invention typically are oilsoluble or miscible with the oil soluble external phase materials,especially at the temperature at which the lipid material melts. It alsoshould have a relatively low HLB value. Emulsifiers suitable for use inthe present invention have HLB values typically in the range of fromabout 1 to about 7 and can include mixtures of different emulsifiers.Preferably, these emulsifiers will have HLB values from about 1.5 toabout 6, and more preferably from about 2 to about 5.

[0188] A wide variety of emulsifiers are useful herein and include, butnot limited to, those selected from the group consisting of sorbitanesters, glyceryl esters, polyglyceryl esters, methyl glucose esters,sucrose esters, ethoxylated fatty alcohols, hydrogenated castor oilethoxylates, sorbitan ester ethoxylates, polymeric emulsifiers, andsilicone emulsifiers.

[0189] Sorbitan esters are useful in the present invention. Preferableare sorbitan esters of C₁₆-C₂₂ saturated, unsaturated and branched chainfatty acids. Because of the manner in which they are typicallymanufactured, these sorbitan esters usually comprise mixtures of mono-,di-, tri-, etc. esters. Representative examples of suitable sorbitanesters include sorbitan monooleate (e.g., SPAN® 80), sorbitansesquioleate (e.g., Arlacel® 83), sorbitan monoisostearate (e.g., CRILL®6 made by Croda), sorbitan stearates (e.g., SPAN® 60), sorbitantrioleate (e.g., SPAN® 85), sorbitan tristearate (e.g., SPAN® 65),sorbitan dipalmitates (e.g., SPAN® 40), and sorbitan isostearate.Sorbitan monoisostearate and sorbitan sesquioleate are particularlypreferred emulsifiers for use in the present invention.

[0190] Other suitable emulsifiers for use in the present inventioninclude, but is not limited to, glyceryl monoesters, preferably glycerylmonoesters of C₁₆-C₂₂ saturated, unsaturated and branched chain fattyacids such as glyceryl oleate, glyceryl monostearate, glycerylmonopalmitate, glyceryl monobehenate, and mixtures thereof; polyglycerylesters of C₁₆-C₂₂ saturated, unsaturated and branched chain fatty acids,such as polyglyceryl-4 isostearate, polyglyceryl-3 oleate, diglycerolmonooleate, tetraglycerol monooleate and mixtures thereof; methylglucose esters, preferably methyl glucose esters of C₁₆-C₂₂ saturated,unsaturated and branched chain fatty acids such as methyl glucosedioleate, methyl glucose sesquiisostearate, and mixtures thereof;sucrose fatty acid esters, preferably sucrose esters of C₁₂-C₂₂saturated, unsaturated and branched chain fatty acids such as sucrosestearate, sucrose trilaurate, sucrose distearate (e.g., Crodesta® F10),and mixtures thereof; C₁₂-C₂₂ ethoxylated fatty alcohols such asoleth-2, oleth-3, steareth-2, and mixtures thereof; hydrogenated castoroil ethoxylates such as PEG-7 hydrogenated castor oil; sorbitan esterethoxylates such as PEG-40 sorbitan peroleate, Polysorbate-80, andmixtures thereof; polymeric emulsifiers such as ethoxylated dodecylglycol copolymer; and silicone emulsifiers such as laurylmethiconecopolyol, cetyldimethicone, dimethicone copolyol, and mixtures thereof.

[0191] In addition to these primary emulsifiers, the compositions of thepresent invention can optionally contain a coemulsifier to provideadditional water-lipid emulsion stability. Suitable coemulsifiersinclude, but is not limited to, phosphatidyl cholines and phosphatidylcholine-containing compositions such as lecithins; long chain C₁₆-C₂₂fatty acid salts such as sodium stearate; long chain C₁₆-C₂₂dialiphatic, short chain C₁-C₄ dialiphatic quaternary ammonium saltssuch as ditallow dimethyl ammonium chloride and ditallow dimethylammonium methylsulfate; long chain C₁₆-C₂₂dialkoyl(alkenoyl)-2-hydroxyethyl, short chain C₁-C₄ dialiphaticquaternary ammonium salts such as ditallowoyl-2-hydroxyethyl dimethylammonium chloride; the long chain C₁₆-C₂₂ dialiphatic imidazoliniumquaternary ammonium salts such as methyl-1-tallow amido ethyl-2-tallowimidazolinium methylsulfate and methyl-1-oleyl amido ethyl-2-oleylimidazolinium methylsulfate; short chain C₁-C₄ dialiphatic, long chainC₁₆-C₂₂ monoaliphatic benzyl quaternary ammonium salts such as dimethylstearyl benzyl ammonium chloride, and synthetic phospholipids such asstearamidopropyl PG-dimonium chloride (Phospholipid PTS from MonaIndustries).

[0192] WEIGHT RATIOS AND WEIGHT PERCENTAGES

[0193] In the present invention, the weight ratio of the latheringsurfactant to the conditioning component is preferably less than about40:7, more preferably less than about 5:1, even more preferably lessthan about 2.5:1, and most preferably less than about 1:1.

[0194] In certain preferred embodiments of the present invention, thecleansing and conditioning component, which is defined as comprising alathering surfactant and a conditioning component further comprising anoil soluble conditioning agent and a water soluble conditioning agent,the lathering surfactant comprises from about 1% to about 75%,preferably from about 10% to about 65%, and more preferably from about15% to about 45%, by weight of the cleansing and conditioning component,and the conditioning component comprises from about 15% to about 99%,preferably from about 20% to about 75%, and more preferably from about25% to about 55%, by weight of the cleansing and conditioning component.

[0195] ADDITIONAL INGREDIENTS

[0196] The compositions which are added onto or impregnated into thearticles of the present invention may comprise a wide range of optionalingredients. Particularly useful are added polymers (as distinct fromthe polymeric material which may form the substrate), various activeingredients, and cationic surfactants useful for delivering variousnon-conditioning or non-cleansing benefits of the skin or hair duringthe cleansing and conditioning process. Additional ingredients of thesetypes are described in greater detail in Procter & Gamble; PCTApplication No. WO 99/13861; published Mar. 25, 1999 (P&G Case 6840).This document is incorporated herein by reference.

[0197] Other Optional Ingredients

[0198] The articles of the present invention can comprise a wide rangeof other optional components. These additional components should bepharmaceutically acceptable. The CTFA Cosmetic Ingredient Handbook,Second Edition, 1992, which is incorporated by reference herein in itsentirety, describes a wide variety of nonlimiting cosmetic andpharmaceutical ingredients commonly used in the skin care industry,which are suitable for use in the compositions of the present invention.Nonlimiting examples of functional classes of ingredients are describedat page 537 of this reference. Examples of these and other functionalclasses include: abrasives, absorbents, anticaking agents, antioxidants,vitamins, binders, biological additives, buffering agents, bulkingagents, chelating agents, chemical additives, colorants, cosmeticastringents, cosmetic biocides, denaturants, drug astringents, externalanalgesics, film formers, fragrance components, humectants, opacifyingagents, pH adjusters, preservatives, propellants, reducing agents, skinbleaching agents, and sunscreening agents.

[0199] Also useful herein are aesthetic components such as fragrances,pigments, colorings, essential oils, skin sensates, astringents, skinsoothing agents, and skin healing agents.

[0200] METHODS OF MANUFACTURE

[0201] The disposable, single use personal care cleansing articles ofthe present invention can be manufactured by separately orsimultaneously adding onto or impregnating into a water-insolublesubstrate a lathering surfactant and optionally a conditioningcomponent. If necessary, the resulting article can then be dried. By“separately” is meant that the surfactants and conditioning agents canbe added sequentially, in any order without first being combinedtogether. By “simultaneously” is meant that the surfactants andconditioning agents can be added at the same time, with or without firstbeing combined together. For the preferred embodiment containing twolayers, the lathering surfactant and/or the conditioning component canalso be added onto or impregnated into either layers (100 or 200) in anysequence. Alternatively, the lathering surfactant and/or theconditioning component can be added onto or impregnated into theresulting combination of the first layer 100 and the second layer 200.Treatment with the lathering surfactant and/or the conditioningcomponent can be achieved at anytime before or after joining the firstlayer 100 and the second layer 200. Despite the order of treatment,excess surfactant and/or conditioning component should be removed (e.g.,by a nipping process). Thereafter, the treated material (e.g., the firstlayer 100, the second layer 200, both layers 100 and 200, or joinedsubstrate) should be dried by conventional means.

[0202] For example, prior to joining the first layer 100 to the secondlayer 200, the second layer can be treated with the latheringsurfactant. After joining the two layers, either of the outside surfaces(e.g., the unjoined surfaces) of layers 100 and/or 200 can be treatedwith the conditioning component. Alternatively, the latheringsurfactants and conditioning agents can be added onto or impregnatedinto the second layer 200 at the same time prior to joining the twolayers. Alternatively, the lathering surfactants and the conditioningagents can be combined together before adding onto or impregnating intothe second layer 200.

[0203] Alternatively, prior to joining the two layers, the first layer100 can be treated with the lathering surfactant employing methods whichdo not cause the first layer to elongate or extend. This can be achievedin the manufacturing of the first layer or by various applicationmethods well known to those of ordinary skill in the art. Nonlimitingexamples of application methods include extrusion coating and slotcoating.

[0204] The surfactant, conditioning agents, and any optional ingredientscan be added onto or impregnated into either layer (100 or 200) or theresulting joined layers (100 and 200) by any means known to thoseskilled in the art: for example, by spraying, laser printing, splashing,dipping, soaking, or coating.

[0205] When water or moisture is used or present in the manufacturingprocess, the resulting treated substrate is then preferably dried sothat it is substantially free of water. The treated substrate can bedried by any means known to those skilled in the art. Nonlimitingexamples of known drying means include the use of convection ovens,radiant heat sources, microwave ovens, forced air ovens, and heatedrollers or cans. Drying also includes air drying without the addition ofheat energy, other than that present in the ambient environment. Also, acombination of various drying methods can be used.

[0206] Preferably, upon wetting with water during use, the articles ofthe present invention are capable of generating an Average Lather Volumeof greater than or equal to about 30 ml, more preferably greater than orequal to about 50 ml, even more preferably greater than or equal toabout 75 ml, and most preferably greater than or equal to about 150 ml.

[0207] METHODS OF CLEANSING AND CONDITIONING THE SKIN OR HAIR

[0208] The present invention also relates to a method of cleansing andconditioning the skin or hair with a personal cleansing article of thepresent invention. These methods comprise the steps of wetting withwater a substantially dry, disposable, single use personal cleansingarticle comprising a water insoluble substrate, a lathering surfactant,and optionally a conditioning component, and contacting the skin or hairwith such wetted article. In further embodiments, the present inventionis also useful for delivering various active ingredients to the skin orhair.

[0209] The articles of the present invention are preferablysubstantially dry and are intended to be wetted with water prior to use.The article is wetted by immersion in water or by placing it under astream of water. Lather is generated from the article by mechanicallyagitating and/or deforming the article either prior to or during contactof the article with the skin or hair. Preferably, upon wetting, thearticles of the present invention generate an Average Lather Volume ofgreater than or equal to about 30 ml, more preferably greater than orequal to about 50 ml, even more preferably greater than or equal toabout 75 ml, and most preferably greater than or equal to about 150 ml.The resulting lather is useful for cleansing and conditioning the skinor hair. During the cleansing process and subsequent rinsing with water,the conditioning agents and active ingredients are deposited onto theskin or hair. Deposition of conditioning agents and active ingredientsare enhanced by the physical contact of the substrate with the skin orhair.

[0210] Without being limited by theory it is believed that the substratesignificantly contributes to generation of lather and deposition ofconditioning agents and any other active ingredients. It is believedthat this increase in lathering and deposition is the result of thesurface action of the substrate. As a result, milder and significantlylower amounts of surfactants may be employed. The decreased amount ofrequired surfactant is believed to relate to the decrease in the dryingeffect of the skin or hair by the surfactants. Furthermore, thediminished amount of surfactant dramatically lowers the inhibitoryaction (e.g., via emulsification or direct removal by the surfactants)which surfactants exhibit regarding deposition of conditioning agents.

[0211] Further without being limited by theory, it is believed that thesubstrate also enhances deposition of conditioning agents and activeingredients. Since the invention is in dry form, the invention does notrequire emulsifiers, which can inhibit deposition of conditioning agentsand active ingredients. Furthermore, because the skin conditioners andactive ingredients are dried onto or impregnated into the substrate,they are transferred directly to the skin or hair by surface contact ofthe wetted article to the skin.

[0212] The substrate also enhances cleansing. The apertured substratecan have differing textures on each side, e.g. a rough side and a smoothside. The apertured substrate acts as an efficient lathering andexfoliating implement. By physically coming into contact with the skinor hair, the substrate significantly aids in cleansing and removal ofdirt, makeup, dead skin, and other debris.

[0213] Finally, an apertured substrate having at least a portion that iswet extensible provides the desired qualities (e.g., proper texture,thickness, and bulk) of a washcloth. It is also believed that theseparticular types of apertured substrates enhance lather generation.

EXAMPLES

[0214] The following examples further describe and demonstrateembodiments within the scope of the present invention. In the followingexamples, all ingredients are listed at an active level. The examplesare given solely for the purpose of illustration and are not to beconstrued as limitations of the present invention, as many variationsthereof are possible without departing from the spirit and scope of theinvention.

[0215] Ingredients are identified by chemical or CTFA name, and allweights are in percent actives.

Examples 1-5

[0216] I. The Substrate

[0217] A multi-layered substrate, as described in FIGS. 1, 2, 3, 4, 5A,and 5B, is prepared as herein described. The portion of the substratewith the cleansing area is fashioned from non-apertured hydroentanglednonwoven material. The second substrate laminated onto the non-aperturedsubstrate is fashioned from a wet-laid process, comprised of 100% pulp.The wet-laid web contains apertures averaging in size about 2-3 mm indiameter, spaced at a frequency of about 3 per cm.

[0218] II. The Surfactant Phase

[0219] In a suitable vessel, the following ingredients are mixed at roomtemperature. Add heat as necessary to obtain uniformity. Weight PercentIngredients Example 1 Example 2 Example 3 Example 4 Example 5 Water QS100 QS 100 QS 100 QS 100 QS 100 Polyguaternium-10 — 0.25 — — — PEG 14M —0.5  0.5 — — Hydroxypropyltrimonium — — — — 0.25 ChlorideHydroxyelthylcellulose 0.25 — — — 0.5  Guar Gum 0.25 — — — —

[0220] The following components are added to the mixture of the abovecomponents. Disodium EDTA 0.10 0.10 0.10 0.10 0.10 Sodium LauroylSarcosinate 3.33 3.33 3.33 3.33 3.33 Sodium Lauroamphoacetate — — — —3.33 Cocamidopropyl Betaine 3.33 3.33 3.33 3.33 — Decyl Polyglucoside3.33 3.33 3.33 3.33 3.33 Methyl Paraben 0.25 0.25 0.25 0.25 0.25Phenoxyethanol 0.3 0.3 0.3 0.3 0.3 Benzyl Alcohol 0.3 0.3 0.3 0.3 0.3Glycerin — — — — 3.0 Urea — 1.0

[0221] In a separate mixing vessel, the following components are added.The combination is mixed (with heat to 40° C. as necessary) until propylparaben is dissolved. Water 2.0 2.0 2.0 2.0 2.0 Butylene Glycol 2.0 2.02.0 2.0 2.0 Propyl Paraben  0.15  0.15  0.15  0.15  0.15

[0222] This mixture is added to the first mixing vessel. About 1.5-2.5 gof the resultant mixture are applied to the hydroentangled non-wovensubstrate and then dried.

[0223] III. Optional Lipid Phase

[0224] In a suitable vessel, the following components are mixed withheat until molten (between 75-115° C.). SEFA* Cottonate 48.00 48.0048.00 48.00 48.00 SEFA* Behenate 12.00 — — — — Vitamin E Acetate — 2.02.0 2.0 2.0 Petrolatum 10.00 10.00 10.00 10.00 23.00 Tribehenin 5.00 5.05.0 5.0 5.0 C₁₀-C₃₀ Cholesterol/ 25.00 23.00 23.00 23.00 10.00Lanosterol Esters Synthetic Beeswax — 3.0 3.0 3.0 — Polyethylene Wax —9.0 9.0 9.0 — Paraffin — — — — 12.00 Amount added to cloth 0.25 0.250.35 0.10 0.25

[0225] The amount of this phase (shown in the above table) is applied tothe substrate already containing the materials from the Surfactant andWater-Soluble Conditioner phases, or alternatively, to the wet-laidpaper substrate, which is bonded to the hydroentangled substrate withadhesive, as mentioned previously. The lipid phase is applied in aliquid/molten state (e.g., at or above the melting temperature of theresulting lipid mixture) and then cooled. The resulting cleansingarticle is used by wetting with water and is useful for simultaneouslycleansing the skin or hair and depositing the conditioning agents ontothe skin or hair in a consistent manner.

Examples 6-10

[0226] I. The Substrate

[0227] A single-layered hydroentangled/hydroapertured substratecomprising 70% rayon/30% polyester manufactured by PGI (Chicopee 5763)Such a substrate has apertures of about 2 mm dispersed within it at afrequency of about 3 apertures per centimeter.

[0228] II. The Surfactant Phase

[0229] In a suitable vessel, the following components are mixed at roomtemperature. The mixture is heated as necessary to obtain uniformity.Weight Percent Ingredients Example 6 Example 7 Example 8 Example 9Example 10 Water QS 100 QS 100 QS 100 QS 100 QS 100 Polyguatemium-10 —0.25 — — — PEG 14M — 0.5  0.5 — — Hydroxypropyltrimonium — — — — 0.25Chloride Hydroxyelthylcellulose 0.25 — — — 0.5  Guar Gum 0.25 — — — —

[0230] The following components are added to the mixture of the abovecomponents Disodium EDTA 0.10 0.10 0.10 0.10 0.10 Sodium LauroylSarcosinate 3.33 3.33 3.33 3.33 3.33 Sodium Lauroamphoacetate — — — —3.33 Cocamidopropyl Betaine 3.33 3.33 3.33 3.33 — Decyl Polyglucoside3.33 3.33 3.33 3.33 3.33 Methyl Paraben 0.25 0.25 0.25 0.25 0.25Phenoxyethanol 0.3 0.3 0.3 0.3 0.3 Benzyl Alcohol 0.3 0.3 0.3 0.3 0.3Glycerin — — — — 3.0 Urea — 1.0

[0231] In a separate mixing vessel, the following components are added.The combination is mixed (with heat to 40° C. as necessary) until propylparaben is dissolved. Water 2.0 2.0 2.0 2.0 2.0 Butylene Glycol 2.0 2.02.0 2.0 2.0 Propyl Paraben  0.15  0.15  0.15  0.15  0.15

[0232] This mixture is added to the first mixing vessel. About 1.5-2.5 gof the resultant mixture are added to the non-woven substrate and thendried.

[0233] III. Optional Conditioning Emulsion.

[0234] In a suitable vessel, the following ingredients are mixed withheat until molten (between 75-115° C.). SEFA* Cottonate 27.36 27.3627.36 27.36 27.36 SEFA* Behenate 6.84 — — 6.84 — Polyethylene Wax — 5.136.84 — Synthetic Beeswax — 1.71 — — Petrolatum 5.7 5.7 5.7 5.7 13.1C₁₀-C₃₀ cholesterol/lanosterol 13.1 13.1 13.1 13.1 5.7 esters Vitamin EAcetate 1.14 1.14 1.14 1.14 1.14 Tribehenin 2.85 2.85 2.85 2.85 2.85Decaglyceryl Dipalmitate 0.3 — 0.3 0.3 — Triglyceryl Monostearate 2.70.3 2.7 2.7 0.3 Decaglyceryl Stearate — 2.7 — — 2.7 PolyglycerylTristearate — — — — —

[0235] The following components are then mixed together at roomtemperature until homogeneous. Once the mixture above is completelymelted, heating is stopped and slowly the following components are addedwhile continuing to mix: Water — — 5.0 6.0 5.0 Glycerin 35.0 30.0 25.025.0 21.0 Dex Panthenol — 5.0 3.0 2.0 2.0 Urea — 1.0 — 2.0 1.0 PEG-30 —4.0 2.0 2.0 5.0 Propylene glycol — — 4.0 3.0 5.75 Polyquaternium-10 — —1.0 — 0.25

[0236] About 0.1-1.0 g of this phase in a liquid/molten state is addedto the substrate already containing the materials from the SurfactantPhase. The combination is cooled to room temperature (about 20° C.)after application. The resulting cleansing and conditioning article isused by wetting with water and is useful for cleansing the skin or hairand for depositing the conditioning emulsions onto the skin or hair.

Examples 11, 12 and Comparative

[0237] The following additional examples further describe anddemonstrate embodiments within the scope of the present invention anddocument the effect of aperture size and frequency on latheringperformance.

[0238] I. The Substrate

[0239] Substrates consist of carded, hydroentangled non-wovens comprisedof 70% rayon and 30% polyester. Materials are very close in allproperties, ranging from 67-75 grams per square meter, with the onlyvariable being aperture size and aperture frequency. DescriptionSubstrate Example 11 Example 12 Comparative Example Supplier PolymerGroup Veratec (now Dupont Chicopee Division BBA) Identification NumberChicopee C5763 H140-102 8423 Basis Weight (grams per 70 67 75 squaremeter) Aperture Size (diameter, 2 1 0 * mm) Aperture frequency (#/inch)8 20 N/A *

[0240] II. The Surfactant Phase

[0241] In a suitable vessel, the following ingredients are mixed at roomtemperature. Heat is added as necessary to obtain uniformity. WeightPercent Ingredients Example 11 Example 12 Comparative Example Water QS100 QS 100 QS 100 Polyquaternium-10 0.25 0.25 0.25 PEG 14M 0.5  0.5 0.5 

[0242] The following components are added to the mixture of the abovecomponents. Disodium EDTA 0.10 0.10 0.10 Sodium Lauroyl Sarcosinate 3.333.33 3.33 Cocamidopropyl Betaine 3.33 3.33 3.33 Decyl Polyglucoside 3.333.33 3.33 Methyl Paraben 0.25 0.25 0.25 Phenoxyethanol 0.3 0.3 0.3Benzyl Alcohol 0.3 0.3 0.3

[0243] In a separate mixing vessel, the following components are added.The combination is mixed (with heat to 40° C. as necessary) until propylparaben is dissolved. Water 2.0 2.0 2.0 Butylene Glycol 2.0 2.0 2.0Propyl Paraben 0.15 0.15 0.15

[0244] This mixture is added to the first mixing vessel. About 2.0 gramsof the resultant mixture are added to a non-woven substrate and thendried.

[0245] Lather Performance Data

[0246] Delivering lather quickly is critical to cleansing perception andperformance as well as ease of use for personal cleansing articles insubstrate form. The following method is used to evaluate differences inlather characteristics, specifically how much lather the treatedsubstrate delivers in a short time period (flash lather volume). Themethod involves generation of lather by panelists.

[0247] Instructions/Protocol:

[0248] All measurements are conducted with water temperature at 95° C.

[0249] Wash hands with Ivory bar before starting test. A wash with Ivorybar is also done between products to remove oil/dirt or residue fromprevious cleansers.

[0250] 1) Crumple up the dry substrate product in hand (into a ball).

[0251] 2) Add 10 ml water at 95° C. to wet the substrate product.

[0252] 3) Activate lather by rubbing the substrate in circular motionbetween the hands for 6 seconds.

[0253] 4) Gather lather and scrape into 250 ml beaker.

[0254] 5) Repeat Step (4) four more times (total of 5 reps).

[0255] 6) Discard the product.

[0256] 7) Determine the amount of lather in the beaker to the nearest 5ml.

[0257] 6) Report the amount of lather measured as Flash Volume. LatherPerformance Substrate Example 11 Example 12 Comparative Example FlashLather 175 125 100 Volume (ml)

[0258] It can be seen from the Flash Lather Volume data that the use ofan apertured substrate helps generate lather for the articles of thepresent invention in comparison with a similar article that is preparedfrom a non-apertured substrate.

Examples 13-15

[0259] I. The Substrate

[0260] Substrates consist of composite or laminate material where atleast one of the two materials is apertured to improve lather formation,as observed in the previous set of examples. The apertured andnon-apertured substrate materials can consist of various types ofnon-woven webs (carded, hydroentangled, meltblown, spunbond, SMS, etc.)and/or wet laid paper webs. Description Substrate Example 13 Example 14Example 15 Non apertured + Apertured + Non-apertured + aperturedApertured Apertured Substrate 1 PGI 9950 Veratec H140-102 100% wet laid50/50 Hydroentangled/ paper 40 gsm rayon/polyester hydroaperturednon-apertured 50 gsm. web 70/30 Hydroentangled, rayon/polyesternon-apertured 67 gsm 20 apertures/inch 1 mm diameter Substrate 2Apertured wet Apertured wet Apertured wet laid paper laid paper laidpaper 31 gsm. 31 gsm. 31 gsm. 2-3 mm diameter 2-3 mm diameter 2-3 mmdiameter 3 apertures/cm 3 apertures/cm 3 apertures/cm

[0261] In each instance, Substrate 1 is pattern bonded to Substrate 2 ina configuration similar to that exhibited in FIG. 1 of the drawings.

[0262] II. The Surfactant Phase

[0263] In a suitable vessel, the following ingredients are mixed at roomtemperature. Heat is added as necessary to obtain uniformity. WeightPercent Ingredients Example 13 Example 14 Example 15 Water QS 100 QS 100QS 100 Polyquaternium-10 0.25 0.25 0.25 PEG 14M 0.5  0.5  0.5 

[0264] The following components are added to the mixture of the abovecomponents. Disodium EDTA 0.10 0.10 0.10 Sodium Lauroyl Sarcosinate 3.333.33 3.33 Cocamidopropyl Betaine 3.33 3.33 3.33 Decyl Polyglucoside 3.333.33 3.33 Methyl Paraben 0.25 0.25 0.25 Phenoxyethanol 0.3 0.3 0.3Benzyl Alcohol 0.3 0.3 0.3

[0265] In a separate mixing vessel, the following components are added.The components are then mixed (with heat to 40° C. as necessary) untilpropyl paraben is dissolved. Water 2.0 2.0 2.0 Butylene Glycol 2.0 2.02.0 Propyl Paraben 0.15 0.15 0.15

[0266] This mixture is then added to the first mixing vessel. About 2.5grams of the resultant mixture are added to the non-woven/papercomposites to form cleansing articles of the present invention.

What is claimed is:
 1. A disposable, single use personal care cleansingproduct comprising: (A) a water insoluble nonwoven substrate; and (B) alathering surfactant component; wherein, the substrate contains aplurality of apertures; and wherein, the product is substantially dry.2. The product according to claim 1, wherein the apertures arehydroapertured.
 3. The product according to claim 1, wherein the surfacearea of the product is from 1 to 144 square inches (6.45 cm² to 928.8cm²).
 4. The product according to claim 1, wherein the substrate's basisweight is from 30 gsy to 115 gsy.
 5. The product according to claim 1,wherein the substrate is a hydroentangled nonwoven substrate.
 6. Theproduct according to claim 1, wherein the substrate is resin bonded.